Interior rearview mirror assembly with polymeric components

ABSTRACT

An interior rearview mirror assembly for vehicles incorporates a rearview mirror housing assembly having a polymeric rearview mirror housing and a reflective mirror element, a polymeric rearview mirror support, a polymeric rearview mirror mount, and first and second polymeric ball pivot members received in respective sockets allowing pivotal adjustment of the rearview mirror housing assembly. At least one electrical conductor connects an electrical accessory in the mirror housing assembly to the vehicle electrical system. The rearview mirror support includes a cable-way such that the presence of the electrical conductor as it passes through the ball pivot members and the cable-way is concealed from view while being protected therein even while the ball pivot members are pivoted for adjustment. The various polymeric elements of the assembly are preferably molded in the same color such as black, or alternately in at least two different colors.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/887,298, filed Jul. 8, 2004, entitled INTERIOR REARVIEW MIRRORASSEMBLY WITH POLYMERIC COMPONENTS, which is a continuation of Ser. No.10/032,401, filed Dec. 20, 2001, now U.S. Pat. No. 6,877,709 whichclaims priority on U.S. provisional patent applications Ser. No.60/317,701, filed Sep. 6, 2001, entitled REARVIEW MIRROR SUPPORTASSEMBLY and Ser. No. 60/257,477, filed Dec. 21, 2000, entitled REARVIEWMIRROR SUPPORT ASSEMBLY, the disclosures of all of which are herebyincorporated by reference herein.

FIELD OF THE INVENTION

This invention relates to rearview mirrors for vehicles and, moreparticularly, to interior vehicular rearview mirror assemblies providingimproved support capacity, versatility, vibration performance,resistance to damage, and ease of manufacture.

BACKGROUND OF THE INVENTION

Interior rearview mirror assemblies for vehicles are typically supportedat the forward portion of the passenger compartment of the vehicle by asupport or linkage which is most often secured either to the insidesurface of the windshield or to a mounting assembly at the forward edgeof the headliner on the interior vehicle roof. In either case, amounting assembly includes a support arm connected to the rearviewmirror assembly, the support arm typically including a pair of ballpivot joints allowing adjustment of the position of the rearview mirrorassembly for proper vision by various vehicle drivers. A widely used,conventional support arm is that shown in U.S. Pat. No. 4,254,931 andincludes a metallic cylindrical tube receiving a ball member at each endwithin a polymeric ball receiving cup, the cups and ball members beingseparated by a coil spring which urges the cups and ball members againstthe crimped outer ends of the tube for proper frictional engagement.However, these rearview mirror support arms have been difficult tomanufacture and have encountered numerous drawbacks in use. For example,during high volume production of such supports, it is difficult tomaintain the constant, consistent torque requirements for the ball pivotjoints in order to properly support the rearview mirror assembly in itscantilevered position. Once the outer tube of the conventional supportarm is crimped over at its ends, it cannot be adjusted. If thefrictional resistance or torque required for pivotal movement is notcorrect, the assembly must be scrapped. Moreover, each support armrequires a relatively large number of parts such that the arm isexpensive to manufacture. In addition, since the outer tube of suchassemblies is normally formed from metal, it is necessary that the tubebe properly painted to match or coordinate with the interior color ofthe vehicle or mirror assembly or to reduce glare. Once the assembly isproperly painted, handling of the assembly during manufacture, shippingand/or installation can often damage the paint, again requiring theassembly to be discarded. Further, since the internal spring of suchassemblies causes the frictional resistance at the two ball joints to beinterdependent on one another, it is difficult to adjust the frictionalresistance of each ball joint without affecting the resistance of theother joint. Also, because of the internal structure of the prior knownsupport arms, it has been difficult to insert electrical wiringtherethrough for connection to electrical components mounted in therearview mirror assembly. Moreover, it has been difficult to use thesupport arm area for support of any additional components which addweight to the overall assembly.

In addition, for heavier, more complex rearview mirror assemblies, theconventionally known mounting brackets and windshield mounting memberswhich secure the assembly to the interior surface of the vehiclewindshield have been subject to failure due to the increased weightwhich must be supported in cantilever fashion. Over time, during thesupport of such heavier rearview mirror assemblies, many prior knownbrackets and mounting members have suffered from adhesive failurecausing the assembly to drop from the windshield area.

Accordingly, there is a need in the vehicle industry for improvedsupport capability and versatility for interior rearview mirrorassemblies which have increased complexity and weight due to theinclusion of a greater number of added feature components, as well asimproved vibration performance and ease and cost of manufacture.

SUMMARY OF THE INVENTION

The present invention provides an improved rearview mirror assembly forvehicles. In particular, this invention provides an interior rearviewmirror assembly having polymeric components including a mirror supportand mounting elements with improved performance and ease of manufacture.

In one aspect, the invention is an interior rearview mirror assemblysuitable for use in a vehicle comprising a rearview mirror mount formedfrom polymeric material having a first color, said rearview mirror mountadapted for attachment to one of a windshield portion of the vehicle anda header portion of the vehicle. The assembly further includes arearview mirror housing formed from polymeric material having a secondcolor and a reflective rearview mirror element included in the housing.The assembly further includes a rearview mirror support formed frompolymeric material having a third color, as well as a first pivotelement formed from a polymeric material having a fourth color, and asecond pivot element formed from a polymeric material having a fifthcolor. The support is pivotally attached to the mirror mount by thefirst pivot element while the rearview mirror housing is pivotallyattached to the support by the second pivot element. Each of the mirrormount, mirror support, rearview mirror housing, and first and secondpivot elements is formed in its respective color by molding frompolymeric material of that color.

In one form, the rearview mirror housing further includes at least oneelectrical accessory. The assembly includes electrical conductors forelectrically connecting the electrical accessory to the vehicleelectrical system. The conductors extend through the first and secondpivot elements and the mirror support to the rearview mirror housing.

In other forms, the mirror mount, mirror support and mirror housing, aswell as the first and second pivot elements are each formed insubstantially the same color. One such color is black. Thus, the first,second, third, fourth and fifth colors may all be substantially thesame.

In yet another form, at least two of the mirror mount, mirror support,rearview mirror housing and first and second pivot elements are moldedfrom polymeric materials of different colors.

In other aspects, the support may be a hollow sleeve having a passagewaytherethrough communicating with openings at the opposite ends of thesleeve. Each of the opposite ends defines a socket, each end including aplurality of slots extending toward the other end and parallel to theaxis to define flanges therebetween. A spring-receiving surface isincluded proximate each end for receiving a spring member thereon. Anexternal spring, such as an annular split ring, is received on eachspring-receiving surface to engage the flanges and confine a ball pivotmember when received in the socket and to help define a pivot torque forthe ball pivot member therein. Two ball pivot members may each includean aperture therethrough in communication with a passageway through thesleeve to provide an electrical wire receiving channel definedinternally through the support. Alternately, electrical bus bars may beprovided through or molded in the sleeve.

In another aspect, one of the opposite ends of the support may include asocket, the end including a plurality of slots extending toward theother end and parallel to the axis to define flanges therebetween, aspring-receiving surface proximate that end and an external springmember received on the spring-receiving surface to engage the flanges,while the opposite end includes a partially spherical exterior surfacedefining a ball pivot surface adapted to be received in a socket onanother component of the rearview mirror assembly.

In another embodiment, the sleeve may include a socket at each end forreceiving a ball pivot member within the passageway, the sleeve beingsubstantially continuous along its length intermediate the opposite endsas well as circumferentially therearound, the sleeve also being sizedand formed from a material having sufficient resiliency to frictionallyresist pivotal movement of the ball members when received with aninterference fit in the first and second sockets.

In any of these versions of the support, the sleeve may have a firstlateral exterior dimension measured transverse to the axis at a positionintermediate the opposite ends, while each of the opposite ends has asecond lateral exterior dimension less than or equal to the firstdimension. Preferably, the sleeve is circular in section with the firstand second lateral dimensions being diameters of circular sections atspaced positions along the sleeve.

Additionally, in any of the support embodiments, either the sockets orthe ball pivot members may include surfaces providing enhancedfrictional resistance to movement of the ball pivot member when receivedin the socket, one example of such a surface being a plurality of microprotrusions. Stiffening inserts and/or dampening members may be includedto reduce or dampen vibration. In addition, the sleeve may berectilinear or angled such that the axis at one end extends at an angleto the axis at the other end.

A vehicle accessory may also be mounted or supported in the internalpassageway of any of the sleeves.

In yet another aspect of the invention, an interior rearview mirrorassembly for a vehicle includes a reflective mirror element housed in amirror housing, a first mount on the mirror housing for pivotallyengaging a rearview mirror support, a second mount spaced from the firstmount on the mirror housing for pivotally engaging a second rearviewmirror support, and at least two rearview mirror supports, a first ofthe mirror supports pivotally engaging the first mount, and a second ofthe mirror supports pivotally engaging the second mount. Thus, themirror housing and reflective element are adjustably supported incantilevered position by the first and second mirror supports whenmounted on the interior of a vehicle. The mirror support used in thisaspect of the invention may comprise those of the invention describedabove, or other mirror supports. In addition, three or more mirrorsupports may be included and pivotally engaged with the mirror housingfor greater support of the housing on the vehicle.

In a further aspect of the invention, a vehicle accessory mountingmember or rearview mirror mount for supporting a rearview mirrorassembly or other vehicle accessory includes a base having a top end, abottom end, opposing sides, and front and rear surfaces. A pair ofcooperating receiving members on the rear surface of the base slidablymount the mounting member on an attachment member secured to theinterior portion of a vehicle, such as a windshield. A arm projects fromthe base, the mounting arm extending outwardly from a central positionon the front surface of the base intermediate the top and bottom endsand having an engaging member for pivotally engaging a vehicle accessorysuch as a rearview mirror. A retainer or fastener for engaging andholding the mounting member to the adjustment member may be included,such as a set screw.

Preferably, the receiving members may include a pair of spaced slidesurfaces which preferably extend from adjacent the top end to adjacentthe bottom end of the rear base surface, the slide surfaces being spacedcloser together at the top end and inclined inwardly toward one anotherfor engagement with the outwardly tapered side surfaces of a wedgeshaped attachment member. The slide surfaces preferably comprise a pairof spring flanges projecting outwardly from the rear base surface forresiliently engaging the attachment member. Alternately, a spaced pairof spring bands extend around the front surface of the base, one springband mounted between the support end and top end of the base, while theother spring band is mounted between the support arm and the bottom endof the base. Each spring band has two free ends which project outwardlyof the rear base surface, the free ends of said spring bands togetherdefining said slide surfaces.

In a yet further embodiment of the mount, the receiving members mayinclude frangible portions adapted to release upon application of asufficient force to the mounting member whereby the mounting member willbe released from the attachment member.

In another embodiment of the mount, the spring flanges may be formed ona one-piece spring member which is slidably mounted on the rear basesurface and includes a top flange positioned between the spring flanges,the top flange adapted to be flexed from between the spring flanges uponmounting on the attachment member whereby the spring flanges snap intoengagement with the side surfaces of the attachment member.

In further embodiments, the mounting member or mount and/or the mirrorsupport/stay and the pivot joints incorporated therein may be moldedfrom a resinous, polymeric material and include a metallic or otherstiffening insert to help reduce vibration. The mounting member may alsoinclude a pivotal, securing lever for retention on the windshieldattachment member.

Various forms of mirror stays for supporting rearview mirror assembliesor other vehicle accessories from a windshield attachment member or theheader area above the windshield are provided in other aspects of theinvention. These stays include a socket or ball pivot member and mayinclude breakaway mounts for attachment to the vehicle.

In yet another aspect of the invention, an attachment member forsupporting a rearview mirror assembly or other vehicle accessory on awindshield or other surface includes a body having front, back, top andbottom surfaces and opposing side edges. The back surface is adapted tobe secured to a vehicle support surface such as a windshield. The frontsurface has at least one raised projection thereon defining raisedcontact areas for engaging mating surfaces on an accessory supportmember. The body is larger than the raised projection and has a shapeselected from the group including a rectangle, a circle, truncatedtriangle, a keyhole shape, a rectangle with one rounded end, a truncatedtriangle with one rounded comer, a circle with oppositely extendingrectangular flanges, a T, a cross, an X and an X with an additionalcross member. The base may also include a series of apertures fordecreasing its weight, while the raised projection may have a shapeselected from the group including a circle, wedge having outwardlytapered sides, and a polygon with multiple side surfaces.

Accordingly, the present invention significantly eases manufacturing andlowers costs by eliminating a number of parts from the interior rearviewmirror support assembly while enhancing the ability to maintain desiredresistance to pivotal movement incorporated in the ball pivot joints ona high production basis. The support may be formed in many shapes,configurations and lengths, and may be solid or hollow, while the pivotforce of the joint at one end of the support may be set independently ofthe pivot force at the opposite end by incorporating different strengthexternal springs, different materials and different engaging surfaces onthe sockets and ball pivot members. The invention further provides agreater choice of materials including resinous polymeric materials whichmay be molded in a desired color without requiring conventional paintingprocedures, or decorated and/or coated during or after molding.Moreover, the ball pivot members can be formed from differing materialssuch as polymeric resinous material in a desired color which mayoptionally match the color of the support sleeve. In addition, thepresent invention provides a rearview mirror support having increasedstability and vibration resistance including the simultaneous use of twoor more mirror support assemblies at spaced positions on the housing forthe rearview mirror assembly. Further, the present invention resistsadhesive failure of the support from the vehicle interior surface onwhich it is mounted, such as the interior windshield surface, byincluding an enlarged attachment member or windshield mounting buttonhaving an increased footprint for attachment to the windshield.Moreover, a vehicle accessory mounting member adapted to cooperate withsuch an attachment member provides a centrally located support arm whichdecreases the tensile or peeling force acting on the attachment memberwhile also including a variety of forms of frangible or resilient,spring-type receiving members which engage the attachment member yetbreak away upon impact.

These and other objects, advantages, purposes and features of theinvention will become more apparent from a study of the followingdescription taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first embodiment of the rearviewmirror support for vehicles of the present invention;

FIG. 2 is an exploded, perspective view of the rearview mirror supportof FIG. 1;

FIG. 3 is a perspective view of the support sleeve of the rearviewmirror support of FIGS. 1 and 2;

FIG. 4 is a sectional view of the support sleeve of FIG. 3;

FIG. 5 is a schematic sectional view of the rearview mirror support ofFIGS. 1 and 2 illustrating the internal electrical wire channeltherethrough;

FIG. 6 is a schematic sectional view of a modified form of the rearviewmirror support showing the internal electrical wire channeltherethrough;

FIG. 7 is a rear perspective view of a third embodiment of the rearviewmirror support of the present invention mounted on a rearview mirrorassembly;

FIG. 8 is an exploded perspective view of the rearview mirror support ofFIG. 7;

FIG. 9 is a perspective view of a fourth embodiment of the rearviewmirror support of the present invention;

FIG. 10 is an exploded perspective view of the rearview mirror supportof FIG. 9;

FIG. 11 is a perspective view of the support sleeve of the rearviewmirror support of FIGS. 9 and 10;

FIG. 12 is a side elevation of the support sleeve of FIG. 11;

FIG. 13 is a side section of the support sleeve taken along planeXIII-XIII of FIG. 12;

FIG. 14 is a schematic sectional view of the rearview mirror support ofFIGS. 9 and 10 illustrating the internal electrical wire channeltherethrough;

FIG. 15 is a modified form of the rearview mirror support of FIGS. 1, 25 and 6 also illustrating the internal electrical wire channeltherethrough;

FIG. 16 is a sectional side elevation of yet another embodiment of thesupport sleeve for use in a rearview mirror support of the presentinvention;

FIG. 17 is a rear perspective view of a rearview mirror housingincorporating a pair of ball pivot sockets for receiving a pair ofrearview mirror supports for supporting the housing on a vehicle;

FIG. 18 is a rear perspective view of the mirror housing of FIG. 17incorporating a pair of rearview mirror supports thereon in side-by-sidefashion;

FIG. 19 is a modified version of the rearview mirror housing and supportassemblies shown in FIGS. 17 and 18 incorporating a pair of rearviewmirror supports in over/under configuration;

FIG. 20 is a perspective view of a modified form of rearview mirrorsupport adapted for use with a rearview mirror housing of the type shownin FIGS. 17 and 18;

FIG. 21 is a perspective view of a modified rearview mirror supportincorporating three sockets for ball pivot members on the rearviewmirror housing;

FIG. 22 is a combined front elevation and bottom plan view of one formof rearview mirror housing adapted for use with the present invention;

FIG. 23 is a perspective view of the rear portion of the rearview mirrorhousing of FIG. 22;

FIG. 24 is a rear perspective view of a front bezel or rim taken fromthe bottom and inside for incorporation on the rear housing portion ofFIG. 23;

FIG. 25 is a perspective view of one form of a vehicle accessorymounting member for supporting a rearview mirror or other vehicleaccessory of the present invention;

FIG. 25A is another perspective view of the mounting member of FIG. 25;

FIG. 25B is a rear perspective view of the mounting member of FIG. 25;

FIG. 25C is a side elevation of the mounting member of FIG. 25;

FIG. 25D is a sectional end elevation taken along plane XXV(D)-XXV(D) ofFIG. 25C illustrating mounting on a wedge shaped attachmentmember/windshield mounting button;

FIG. 26 is a rear perspective view of a second embodiment of a vehicleaccessory mounting member of the present invention;

FIG. 26A is a rear elevation of the mounting member of FIG. 26;

FIG. 26B is a rear perspective view of the mounting member of FIG. 26;

FIG. 26C is a side elevation of the mounting member of FIG. 26; and

FIG. 26D is a sectional end elevation taken along plane XXVI(D)-XXVI(D)of FIG. 26C;

FIG. 26E is a rear perspective view of third embodiment of a vehicleaccessory mounting member of the present invention;

FIG. 26F is a sectional view of the mounting member of FIG. 26E takenalong plane XXVIF-XXVIF;

FIG. 27 is a front perspective view of a fourth embodiment of a vehicleaccessory mounting member of the present invention;

FIG. 27A is a rear perspective view of the mounting member of FIG. 27;

FIG. 28 is a top perspective view of a fifth embodiment of a vehicleaccessory mounting member of the present invention;

FIG. 28A is a side elevation of the mounting member of FIG. 28;

FIG. 28B is a top plan view of the mounting member of FIG. 28;

FIG. 28C is a front elevation of the mounting member of FIG. 28;

FIG. 28D is a sectional end elevation taken along planeXXVIII(D)-XXVIII(D) of FIG. 28C;

FIG. 28E is a sectional end elevation taken along planeXXVIH(E)-XXVIII(E) of FIG. 28C;

FIG. 29 is a front perspective view of a eighth embodiment of a vehicleaccessory mounting member of the present invention;

FIG. 29A is a bottom, rear perspective of the mounting member of FIG.29;

FIG. 29B is a rear perspective view of a spring member adapted forinsertion and receipt in the mounting member of FIGS. 29 and 29A;

FIG. 29C is a front elevation of the mounting member of FIG. 29incorporating the spring member of FIG. 29B;

FIG. 29D is a bottom elevation of the mounting member of FIG. 29including the spring member of 29B;

FIG. 29E is a bottom perspective view of the mounting member assembly ofFIG. 29D;

FIG. 29F is a sectional side elevation of the mounting member assemblyof taken along plane XXIX(F)-XXIX(F) of FIG. 29C;

FIG. 29G is a sectional end elevation of the mounting member assemblytaken along plane XXIX(G)-XXIX(G) of FIG. 29C;

FIG. 29H is a sectional end elevation f the mounting member assembly ofFIG. 29C when mounted on of a wedge-shaped attachment member/windshieldmounting button received between the resilient flanges of the springmember of FIG. 29B;

FIG. 291 is a subassembly of the spring member of FIG. 29B incorporatingthe attachment member/windshield button shown in FIG. 29H to illustratethe assembled position of the rear flanges of the spring member;

FIGS. 30-43A are plan views and corresponding side elevations of variousembodiments of a vehicle accessory attachment member/windshield mountingbutton of the present invention illustrating different shapes for boththe attachment body and raised projection thereon;

FIGS. 44 and 44A are a plan view and a corresponding end elevation of awedge shaped projection for use on the vehicle accessory attachmentmembers of FIGS. 30-43A; and

FIGS. 45 and 45A are a plan view and a corresponding side elevation of ahexagonal projection for use on the vehicle accessory attachment membersof FIGS. 30-43A;

FIG. 46 is a sectional side elevation of a further embodiment of thesupport sleeve for use in a rearview mirror support of the presentinvention;

FIGS. 47 and 47A, 48, 48A and 49, 49A are sectional side elevations andperspective views of further embodiments of the support sleeve for usein a rearview mirror support of the present invention and the texturedpivot ball members adapted for providing increased frictional resistanceto pivoting;

FIG. 50 is a sectional side elevation of a modified form of the supportsleeve for use in a rearview mirror support of the present inventionincluding a vibration dampening member therein;

FIG. 51 is a sectional side elevation of yet another embodiment of thesupport sleeve for use in a rearview mirror support of the presentinvention;

FIG. 52 is a side elevation of an insert included in the support sleeveof FIG. 51;

FIG. 53 is an end elevation of the insert shown in FIG. 52;

FIG. 54 is a sectional side elevation of a further embodiment of thesupport sleeve for use in a rearview mirror support of the presentinvention;

FIG. 55 is a sectional end elevation of the support sleeve of FIG. 54;

FIG. 56 is a perspective view of the support sleeve of FIGS. 54 and 55;

FIG. 57 is a perspective view of a reinforcing insert incorporated inthe support sleeve of FIGS. 54-56;

FIG. 58 is a perspective view of another embodiment of the supportsleeve for use in a rearview mirror support of the present invention;

FIG. 59 is an end view of the support sleeve of FIG. 58;

FIG. 60 is a side elevation of the support sleeve of FIGS. 58 and 59;

FIG. 61 is a perspective sectional view of the support sleeve of FIGS.58-60;

FIG. 62 is a front perspective view of a windshield mounted stay of thepresent invention for supporting a rearview mirror assembly or othervehicle accessory;

FIG. 63 is a rear perspective view of the stay of FIG. 62;

FIG. 64 is a side elevation of the stay of FIG. 62;

FIG. 65 is a rear elevation of the stay of FIG. 62;

FIG. 66 is a sectional view of the stay of FIG. 65 taken along planeLXVI-LXVI of FIG. 65;

FIG. 67 is a partial sectional view of the stay of FIG. 62 mounted onthe inside surface of a windshield button of a vehicle;

FIG. 68 is a sectional view taken along plane LXVIII-LXVIII of FIG. 67;

FIG. 69 is a perspective view with portions broken away showing themounting of the stay on a windshield button;

FIGS. 70-72 are alternate forms of the mounting portions of the stay ofFIG. 62;

FIG. 73 is a perspective view of another embodiment of a stay forsupporting a rearview mirror assembly or other vehicle accessoryincorporating the present invention;

FIG. 74 is a front elevation of the stay of FIG. 73;

FIG. 75 is a plan view of the stay of FIG. 73;

FIG. 76 is a sectional view of the stay taken along plane LXXVI-LXXVI ofFIG. 75;

FIG. 77 is a perspective view of the stiffening insert incorporated inthe stay of FIGS. 73-76;

FIG. 78 is a perspective view of a yet further embodiment of a stay ofthe present invention for supporting a rearview mirror assembly or othervehicle accessory;

FIG. 79 is a side elevation of the stay of FIG. 78;

FIG. 80 is a rear elevation of the stay of FIG. 78;

FIG. 81 is a sectional view of the stay taken along plane LXXXI-LXXXI ofFIG. 79;

FIG. 82 is a sectional view of the stay taken along plane LXXXII-LXXXIIof FIG. 80;

FIG. 83 is a front perspective view of a sixth embodiment of a rearviewmirror assembly or vehicle accessory mounting member of the presentinvention;

FIG. 84 is a sectional view of the mounting member of FIG. 83 takenalong plane LXXXIV-LXXXIV;

FIG. 85 is a perspective view of an insert to be integrally molded inthe mounting member of FIG. 84;

FIG. 86 is a perspective view of a seventh embodiment of a rearviewmirror assembly or vehicle accessory mounting member of the presentinvention;

FIG. 87 is an end elevation of the mounting member of FIG. 86;

FIG. 88 is a side elevation of the mounting member of FIG. 86;

FIG. 89 is a perspective view of an insert to be integrally moldedwithin the mounting member of FIG. 86;

FIG. 90 is a perspective view of an ninth embodiment of a rearviewmirror assembly or vehicle accessory mounting member of the presentinvention;

FIG. 91 is a perspective view of a tenth embodiment of a rearview mirrorassembly or vehicle accessory mounting member of the present invention;

FIG. 92 is a sectional side elevation of the mounting member of FIG. 91;

FIG. 93 is a sectional end elevation of the mounting member taken alongplane XCIII-XCIII of FIG. 92;

FIG. 94 is a perspective view of the retaining lever incorporated in themounting member of FIG. 91;

FIG. 95 is a perspective view of an electrical indicator switch usefulwith the present invention;

FIG. 96 is a cutaway, perspective view of the switch of FIG. 95 shownwith portions cutaway;

FIG. 97 is a sectional view of a portion of the plunger of the switch ofFIGS. 95 and 96;

FIG. 98 is yet another embodiment of the rearview mirror support of thepresent invention incorporating an electrical cable or wire housingtherein;

FIG. 98A is an end view of the rearview mirror support of FIG. 98;

FIG. 99 is a modified embodiment of the rearview mirror support of FIG.98 incorporating an electrical cable or wire housing therein on analternate type of mirror support arm;

FIG. 99A is an end view of the rearview mirror support of FIG. 99;

FIG. 100 is a further modified embodiment of the rearview mirror supportof the present invention incorporating a cable or wire housing; and

FIG. 100A is an end view of the rearview mirror support of FIG. 100.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in greater detail, FIGS. 1-5 illustrate afirst embodiment 10 of the rearview mirror support of the presentinvention. Rearview mirror support 10 includes a support memberpreferably comprising a hollow, substantially continuous rearview mirrorsupport element or sleeve 12 having a pair of spaced sockets 14, 16, oneat each opposing end of the sleeve. Each socket is adapted to receive aspherical ball pivot member from a component of the overall rearviewmirror assembly.

For example, socket 14 is adapted to receive ball pivot member 20 formedintegrally with a rearview mirror mounting member, channel mount ormount 18 which can be of a variety of forms as explained more fullybelow. A spring member 22 is received on the exterior of socket 14 tohelp retain ball pivot member 20 in the socket and provide apredetermined frictional resistance to pivotal movement, i.e., apredetermined torque force required for pivoting the ball member in thesocket. Similarly, at the opposite end of sleeve 12, socket 16 isadapted to receive ball pivot member 26 formed integrally with a toggleactuator 24 which is adapted to be pivotally received within a rearviewmirror housing of a rearview mirror assembly. Once again, an externalspring member 28 is adapted to be received on the exterior of socket 16to help retain ball member 26 within the socket and provide apredetermined frictional resistance to pivotal movement or torque forcefor pivoting.

As is best seen in FIG. 3, sleeve 12 is preferably molded in one piecefrom a resinous polymeric material to provide strength and rigidity suchas glass filled nylon (preferably comprising within the range of betweenabout 5 and 30 percent glass), glass filled polypropylene (preferablycomprising within the range of between about 5 and 30 percent glass),and Delrin acetal. Sleeve 12 is preferably tubular and generallycylindrical in shape and has a central axis A extending through acentral passageway 30 which communicates with conically shaped endopenings 32, 34 at the opposite ends of the sleeve. As shown in FIG. 4,passageway 30 may be formed with two conically shaped sections eachjoining the other at the midpoint of the sleeve with each sectionnarrowing from its respective opening to the mid section. The exteriorsurface of sleeve 12 includes generally cylindrical sockets 14, 16 of apredetermined exterior diameter and a recessed central section 36 havinga series of preferably four longitudinally extending strengthening ribs38 extending parallel to central axis A. At a position proximate the endedge of each conically shaped opening 32, 34, on the exterior surface ofeach respective socket 14, 16, is a recessed external, spring-receivingsurface 40, 42, respectively, which is preferably annular and is adaptedto receive an annular spring member such as split ring 22 or 28mentioned above. On the interior of each socket member 14, 16, is apartially spherical surface 44, 46 which may optionally include anannular raised rib or ridge 48, 50 in order to increase the frictionalresistance to movement when a ball pivot member such as that shown inphantom at 26 in FIG. 4 is received in the socket.

Preferably, each socket 14, 16 also includes a series of preferablyeight slots 52, 54 extending inwardly from the outer edges of endopenings 32, 34 in a direction parallel to central axis A, as is bestseen in FIG. 3. Slots 52, 54 allow the individual segments or flanges55, 57 at the ends of sockets 14, 16 which are separated by such slotsto flex outwardly to receive pivot ball member 20 or 26 and to flexinwardly under the tight engagement of annular spring member 22, 28 toretain the ball pivot member in the socket and to tightly engage thesocket with the ball member for proper frictional resistance to pivotalmovement.

Preferably, annular spring members 22, 28 are received on annularsurfaces 40, 42 after ball pivot members 20, 26 on adjacent componentsof the rearview mirror assembly are pressed into sockets 14, 16,respectively. Spring members 22, 28 can be flat, round or circular insection and are preferably circular in overall shape, although springmembers having a polygonal shape, such as hexagonal, or other shapescould also be used. Preferably, each spring member is split and has apredetermined compression force which acts on the ends of the socketflanges between slots 52, 54 when the split ring is received thereover.Preferably, split ring spring members 22, 28 are formed from metalincluding steel, or a polymeric material such as nylon, glass-fillednylon, acetal, or ABS plastic. A suitable spring is a clamp ring formedfrom rounded edge, flat, low carbon steel wire (SAE 1075 steel) obtainedfrom Grand Rapids Spring and Stamp Company of Grand Rapids, Mich., underPart No. 4000573.

When ball pivot members 20, 26 are of the same size or diameter, sockets14, 16 are identical in size and split rings 22, 28 will be identical.However, sockets 14, 16 may be of different sizes with one beingoversized to provide additional surface area to frictionally resistpivotal movement for support of heavier rearview mirror assemblies, ifdesired. Likewise, the materials of rearview mirror support element orsleeve 12 and ball pivot members 20, 26 may be altered to increase ordecrease the torque force or frictional resistance to pivotal movementas desired for support of the rearview mirror assembly in question,while the socket size may also be determined for an interference fitwith the ball size. In addition, the surfaces 44, 46 of sockets 14, 16and the exterior surfaces of the ball pivot members 20, 26 may bealtered for enhanced frictional resistance to movement of the ball pivotmember when received in the socket, such as by providing a plurality ofmicro protrusions on either the socket surface 44, 46 or the exteriorsurface of the ball pivot member itself. In addition, ball pivot members20, 26 may be either formed from metal, such as die cast zinc orsintered powdered metal, or molded from a resinous polymeric material,such as nylon, glass-filled nylon, ABS plastic, or glass-filledpolypropylene, and formed integrally with either rearview mirror mountor mounting member 18 or toggle actuator 24 from a day/night rearviewmirror assembly. When ball pivot members 20, 26 are molded with theirrespective rearview mirror assembly components, they may be colormatched to the color of rearview mirror support element or sleeve 12such that all three are black or another desired color or substantiallysimilar color such as gray, tan, brown, burgundy, green, or othercolors, thereby obviating the need for painting any of these components.Avoiding the painting step not only reduces cost for manufacture of thepresent rearview mirror support, but reduces the risk of damage to thesupport during manufacture, shipping, or installation, thereby reducingthe number of assemblies which must be discarded or scrapped. Likewise,rearview mirror mount or mounting member 18, toggle actuator 24 as wellas any rearview mirror housing in which the toggle actuator is mounted,such as housings 84 or 210 described below, may each be molded from aresinous polymeric material of a desired color, and color matched torearview mirror support element or sleeve 12 and ball pivot members 20,26 such that all are black or another desired color or substantiallysimilar color such as those mentioned above, or others. Alternately, ifdesired, one, two or more of these various components may be molded orformed from polymeric material of a color or colors different from oneor more of the remaining components. For example, the rearview mirrormount or mounting member 18, rearview mirror support element or sleeve12 and rearview mirror housing 84 or 210 can be tan while ball pivotmembers 20, 26 and toggle actuator 24 can be black or burgundy.Alternately, as a further example, rearview mirror mount or mountingmember 18 and rearview mirror support element or sleeve 12 can be tanwhile the remaining components are brown, or black or another color.Further, each component may be molded from a polymeric material having acolor different from each other component. Alternately, the rearviewmirror support element or sleeve may be coated and/or decorated duringor after molding as desired. Use of split spring members 22, 28 alsoallows the rearview mirror support 10 to be disassembled for repair orservice as desired by removing the split ring and withdrawing the ballpivot members 20 and 26 from their respective sockets for repair orreplacement.

As will also be understood from FIGS. 4 and 5, ball pivot members 20, 26may include apertures 56, 58 extending therethrough which communicatenot only with passageway 30 extending through rearview mirror supportelement or sleeve 12 but also the interior of the rearview mirrorassembly through toggle actuator 24 and through the interior of rearviewmirror mounting member, channel mount or mount 18. Thus, one or moreelectrical conductors or wires E (FIG. 5) can be extended from thevehicle electrical system downwardly from the interior header or roofarea of the vehicle along windshield W to opening 19 in the upper end ofmounting member 18 (FIGS. 2 and 5) through rearview mirror mountingmember or mount 18, aperture 56, passageway 30 and aperture 58 to theinterior of the rearview mirror assembly being supported for supplyingelectricity to one or more electrical components secured within themirror assembly. It will, therefore, be understood that rearview mirrorsupport 10 defines an internal electrical wire or conductor channelwhich is concealed from the exterior of the support while confining andprotecting the electrical conductors therein even while ball pivotmembers 20, 26 are pivoted for adjustment of the position of therearview mirror assembly.

Alternately, sleeve 12 may include one or more brass, metallic, or otherelectrically conductive electrical bus bars which, preferably, areinsert molded within the sleeve to extend from one end to the othereither internally or externally. Such bus bars preferably would have asurface exposed at each end of sleeve 12 for connection to anothercomponent of the rearview mirror assembly, or to an electrical connectorand wire/conductor to provide electricity through the sleeve.

With reference to FIG. 6, an alternate embodiment 10′ of the rearviewmirror support is shown which is similar in substantially all respectsto embodiment 10 and wherein like numerals indicated like parts.However, support 10′ includes a modified sleeve 12′ which is tubular buthas differing cross sections at the central and end portions. Morespecifically, sleeve 12′ includes a central section 60 having a lateralexterior dimension of a predetermined size measured transverse to thecentral axis which is preferably larger than that of sleeve 12 andprovides an interior space 61 which may be used to house or supportother vehicle accessories as described below. In addition, sleeve 12′includes recessed opposing ends 62, 64 which may be of the same ordiffering lateral exterior dimension as compared to one another.Preferably, sleeve 12′ is circular in section such that the dimensionsof sections 60, 62, and 64 are diameters. Alternately, the sleeve mayhave varying sectional shapes such as triangular, square, pentagonal,hexagonal, octagonal or the like. In addition, as shown in phantom inFIG. 6, the inside dimensions of the sockets at either end may extendsubstantially continuously across the entire length of sleeve 12′ suchthat the walls of central section 60 are thicker than recessed sections62, 64 for added strength and rigidity such that internal passageway 30is substantially uniform across the entire length of sleeve 12′. Asmentioned above, the materials from which sleeve 12′ is preferablymolded may be selected to enhance the rigidity, natural resiliencyand/or strength of the sleeve member as desired.

Support 10 or 10′ also provides a suitable support area to which othervehicle accessories may be attached or secured such as microphones,camera systems, antennas, cell phone connections or plugs,magneto/compasses, theft alarm systems, headlight dimming sensors, rainsensor systems, and other electronic equipment. As shown in FIG. 6, avehicle accessory 70 may be mounted or secured within interior area 61of central section 60. For example, a radio or cell phone antenna, oneof various sensors, a video accessory or another electrical accessorycould be included. Suitable video accessories, which could be used withthe supports of the present invention, are disclosed in copending,commonly owned, U.S. provisional applications entitled “VIDEO MIRRORSYSTEMS INCORPORATING AN ACCESSORY MODULE”, Ser. No. 60/243,986, filedOct. 27, 2000; “VIDEO MIRROR SYSTEMS, Ser. No. 60/238,483, filed Oct. 6,2000; “VIDEO MIRROR SYSTEMS”, Ser. No. 60/237,077, filed Sep. 29, 2000;“VIDEO MIRROR SYSTEMS”, Ser. No. 60/234,412, filed Sep. 21, 2000;“INTERIOR REARVIEW MIRROR ASSEMBLY INCORPORATING A VIDEO SCREEN”, Ser.No. 60/218,336, filed Jul. 14, 2000; and “INTERIOR REARVIEW MIRRORASSEMBLY INCORPORATING A VIDEO SCREEN”, Ser. No. 60/186,520, filed Mar.2, 2000, which were consolidated into one application and have nowissued as U.S. Pat. No. 6,690,268, the disclosures of which are herebyincorporated by reference herein.

As shown in FIGS. 7 and 8, a further modified embodiment 80 of therearview mirror support is shown wherein like numerals indicate likeparts to those in embodiments 10 and 10′. In embodiment 80, a rearviewmirror assembly 82 including a molded resinous plastic housing 84 of adesired color includes a rear surface 86 through which extends agenerally spherical ball pivot member 88 projecting outwardly from atoggle actuator similar to that shown at 24 in embodiments 10 and 10′which is pivotally mounted within the housing. A modified sleeve 90 isincluded in the rearview mirror support for rearview mirror assembly 82and includes sockets 92, 94 which are substantially similar to sockets14, 16 described above. In this case, however, sleeve 90 includes acurved or bent central section 96 such that the central axis of sockets92, 94 extend at an obtuse angle to one another. Accordingly, whensocket 92 receives ball pivot member 100 from mounting member/channelmount 98 therein, and ball pivot member 88 is received in socket 94 withsplit rings 22, 28 received over sockets 92, 94 for retention of theball pivot member therein as explained above for embodiments 10 and 10′,socket 92 will extend parallel to the support for ball pivot member 100on mounting member 98 while rearview mirror assembly 82 will besupported in an upright, cantilevered position for viewing by the driverof the vehicle on ball pivot member 88 taking into account the angle ofincline of the windshield from which mounting member 98 is supported.Like sleeve 12, 12′, sleeve 90 may be solid or include an internalpassageway for electrical conductors, or include integral, molded in orother electrical bus bars.

Referring now to FIGS. 9-14, a fourth embodiment 110 of the rearviewmirror support is shown wherein like numerals indicate like parts tothose set forth in embodiments 10, 10′ and 80. Support 110 includes ahollow, substantially continuous sleeve 112 preferably molded from thesame resinous polymeric materials set forth above for embodiment 10 andincludes a socket 114 at its forward end and a partially sphericalexterior surface 116 at its opposite rearward end forming a ball pivotmember. Socket 114 is substantially similar in all respects to sockets14 and 16 described above and is adapted to receive ball pivot member 20formed integrally with mounting member/channel mount 18 therein withsplit ring 22 received over socket 14 for retention of the ball pivotmember therein in the manner described above. Ball pivot member 116 isadapted to be received in a socket 122 formed integrally with a modifiedtoggle actuator 24′. Socket 122 is similar in all respects to sockets.14, 16 described above and receives a split ring 28 thereover forretention of ball pivot member 116 within the socket. Sleeve 112includes a center or intermediate section 124 which is conically shapedand extends from a first diameter at the inside end of socket 114 to asmaller diameter at ball pivot member 116 as is best seen in FIGS.10-13. A series of gussets or ribs 126 may be included between socket114 and central section 124 for added strength. A through passageway 128extends from the opening at ball pivot member 116 through the entirelength of sleeve 112 to the opening at socket 114 for receipt ofelectrical wires or conductors in the manner described above and asshown in FIG. 14. In this regard, the electrical conductors E will passthrough passageway 128 from a through aperture in toggle actuator 24′into passageway 56 in mounting member 18 and out of the mounting memberthrough opening 19 to the vehicle electrical system in the mannerdescribed above. Alternately, molded in electrical bus bars may beincluded in sleeve 112. Accordingly, in its various embodiments, thesleeve of the rearview mirror support invention herein my includesockets or a socket and ball member on opposite ends or combinationsthereof as desired for the particular rearview mirror assembly to besupported.

As shown in FIG. 15, a fifth embodiment 140 of the rearview mirrorsupport of the present invention is shown wherein like parts areindicated by like numerals to those described above in connection withprevious embodiments. Support 140 includes a modified continuous sleeve142 similar to sleeve 12′ described above in connection with embodiment10′ but eliminating the annular surfaces on the exterior of end sections144, 146 and eliminating the use of an external spring member or splitring as in the previous embodiments. Sleeve 142 includes a centralsection 148 having a predetermined diameter with end sections 142, 146having reduced diameters. Each end section 142, 146 includes a socket ofthe type shown in FIG. 16 for receiving a ball pivot member such as 20or 26 therein but without the need for a split ring or annular springmember therearound for retention purposes. In this regard, the materialof sleeve 142 is selected to be sufficiently stiff but naturallyresilient to allow the pivot ball member to be pressed into thepartially spherical surfaces 143, 147 formed within the sockets forretention of the ball pivot members and providing sufficient frictionalresistance to pivotal movement for proper retention of rearview mirrorassemblies thereby. Sleeve 142 includes a central passageway 150 thereinthrough which an electrical conductor or wire E may be passed frommounting member 18 and ball pivot member 20 to ball pivot-member 26 andtoggle actuator 24 to the interior of the supported rearview mirrorassembly in the manner described above. Alternately, sleeve 142 mayinclude electrical bus bars which preferably are molded in the sleeve.The interior area of central section 148 which defines a portion ofpassageway 150 may also house or support a vehicle accessory 70 asdescribed above in support 10′ of FIG. 6.

As shown in FIG. 16, an alternate version 142′ of sleeve 142 issubstantially cylindrical and tubular in form and includes asubstantially rectilinear inner passageway 150′ in which socket surfaces143, 147 are formed in the manner described above. Again, the material,wall thickness, shape and overall size of the sleeve are selected toprovide the proper frictional resistance to pivotal movement and supportfor the rearview mirror assembly as needed.

In any of the support embodiments, described herein, sleeve 12, 12′, 90,112, 142 or 142′ may also be solid with the passageway 30, 128, 150therethrough eliminated. In such case, sockets in one or both ends suchas at 14, 16, or ball pivot surfaces such as that at 116 at one or bothends, or a socket at one end and a ball pivot surface at the other end,may be included. When sockets are included in the solid support, theypreferably would include internal spherical surfaces such as 44, 46, andmay optionally include external spring members 22, 28, slots 52, 54,flanges 55, 57, and conical openings 32, 34.

As shown in FIG. 46, a further embodiment 600 of the rearview mirrorsupport (that is preferably formed of a polymeric resin such as byinjection molding) of the present invention is shown including amodified continuous sleeve 602 including a socket 604 adjacent one endfor receiving a ball pivot member preferably compression fitted thereinfor an interference fit within the socket as described above, and asocket 606 at the other end for similarly receiving a ball pivot memberfrom a rearview mirror assembly component as shown in phantom.Preferably, as shown in FIG. 46, sockets 604, 606 each have across-sectional shape which is slightly different from that of agenerally spherical ball pivot member. The diameter of sleeve 602 atleft end 602 a is larger than the diameter of end 602 b such that thatthe wall thickness of the tube adjacent socket 604 is greater than thewall thickness adjacent socket 606. This provides a difference in torqueor frictional resistance to pivotal movement of the ball member based onan interference fit between the ball pivot member received in socket 604and that received in socket 606. Assuming end 602 a of the sleeve 602 ismounted closer to the windshield when the support is used in a vehicle,the wall thickness will be greater adjacent the windshield to provide agreater torque for the ball pivot member received in socket 604 thanthat received in socket 606. Accordingly, adjustment of the ball pivotmember in socket 606 is easier than that for socket 604 therebypreventing undesired adjustment of the major position of sleeve 602 atthe windshield end when the rearview mirror assembly is adjusted bymeans of the ball pivot member received in socket 606.

Another way of achieving a desired pivotal resistance and adjustmenttorque is through the provision of textured ball pivot members and/orsocket surfaces having a textured functionality such as by havingtextures, stipples or protrusions therein. For example, as shown in FIG.47, a molded plastic support element or sleeve 610, such as any of thosedescribed above, may include sockets 612, 614 at opposite ends, eachsocket including a saw tooth surface comprising small, rigid, upstandingridges or sharp protrusions. The pivot ball member 616 adapted to bereceived within socket 612 or 614 has a corresponding saw tooth surfaceas shown in FIGS. 47 and 47A. Each ridge or protrusion preferably has aheight of from about 0.0001 to about 0.05 inches; more preferably fromabout 0.005 to about 0.01 inches; most preferably from about 0.001 toabout 0.005 inches.

Alternately, as shown in FIGS. 48 and 48A, a modified rearview mirrorsupport element or sleeve 610′, preferably formed from polymericmaterial as described below, may include sockets 612′ and 614′, each ofwhich includes a pair of spaced, annular ridges or sharp projections618. In this version, a ball pivot member 616′ includes cross hatchingon its surface as best seen in FIG. 48A for mating with the sharpprotrusions 618 to provide greater resistance to pivotal movement of theball member within the socket as desired. In this embodiment, annularridges 618 preferably have a height of from about 0.005 to about 0.01inches; most preferably from about 0.001 to about 0.005 inches.

As shown in FIGS. 49 and 49A, yet another version of rearview mirrorsupport sleeve 610″ includes sockets 612″ and 614″ each of whichincludes annular recesses 622 therein adapted to mate with smallprotrusions or micro texturing of the surface of ball pivot member 624.Once again, receipt of the protrusions on ball pivot 624 in the recesses622 of socket 612″, 614″ provides increased frictional resistance topivotal movement of the ball member in the socket. The amount ofresistance is dependent upon the size of the protrusions or microprotrusions and recesses formed on the ball member and in the sockets.Preferably, the protrusions have a height of from about 0.005 to about0.01 inches; most preferably from about 0.001 to about 0.005 inches, anda diameter or width in the range of from about 0.0005 to about 0.01inches, and are spaced apart by a distance in the range of from about0.0005 to about 0.01 inches.

The above techniques for modifying and adjusting the frictionalresistance to pivotal movement of the ball pivot members in the socketsof the rearview mirror support sleeves may be used in any of theembodiments of the support sleeve described herein. Preferably, thetorque or frictional resistance to pivotal movement at the end of thesupport sleeve at the windshield or channel mount end of the sleeve ishigher than the frictional resistance to pivotal movement at the endadjacent the rearview mirror assembly. For example, the ratio of thetorque at the windshield or channel mount end to the torque at themirror assembly end is preferably at least about 2 to 1, and morepreferably at least about 3 to 1. The desired torque ranges for thewindshield/channel mount end are in the range of about 0.8 to about 3.6Newton-meters. For the mirror assembly end of the sleeve, the desiredtorque range is from about 0.6 to about 3.2 Newton-meters. The channelmount or windshield end preferably has a minimum of 0.11 Newton-metergreater torque than the mirror assembly end. The difference in torqueallows adjustment of the ball pivot member at the mirror assembly endwithout necessarily adjusting the position of the channel mount orwindshield end of the sleeve.

Other methods for increasing or decreasing the frictional resistance topivotal movement in the interference fit between the ball pivot memberand sockets of the sleeves of the present invention are by providing oneor both surfaces with different materials such as co-injected materials,or by providing coatings such as a grease coating or titanium nitridecoating for modifying the frictional resistance to pivotal movement.

As an example, the rearview mirror support sleeve or tube may be anextruded tube from Ultraform H4320 or Ultraform N2320003, available fromBASF of Mount Olive, N.J., which comprises a nylon resin material. Otherpolymeric (including copolymer) materials can be used, including thosewith additives included. Through the addition of additives to suchmaterials, the smoothness of the material can be reduced. Acetals whichare smooth and self lubricating, may also be used to form the mirrorsupport sleeve. Alternately, the tube may be formed from polypropyleneor a polyphenylene oxide (PPO). Further, the tube may be extruded from amaterial such as Delrin available from I.E. DuPont of Wilmington, Del.,that comprises an acetal resin material.

With reference to FIG. 50, a further embodiment 630 of the rearviewmirror support of the present invention includes a molded plastic,rectilinear, cylindrical sleeve or tube 631 having a socket 632 at thewindshield or channel mount end and a socket 634 at the mirror assemblyend. Sockets 632, 634 are designed to receive ball pivot members thereinwith an interference fit and a desired frictional resistance to pivotalmovement using one or more of the methods described above. In addition,sleeve 631 includes a vibration reducing or dampening element insertedor incorporated in the tube such as a cork, foam (such as polystyrenefoam), thermoplastic elastomer, or urethane dampening plug or member 636press-fitted within the inner diameter of the tube or adhered thereincentrally between sockets 632, 634 with a suitable adhesive and/ormechanically. Alternately, dampening member 636 could be co-injectedwith sleeve 631 from the same or a different material rather thanseparately formed and inserted into the tube after formation of thetube.

Support 631 is adapted to provide improved vibration performance. Forexample, the natural frequency of the mirror assembly to be supported ispreferably either less than or greater than the natural frequency of theoverall vehicle in which it is mounted. As an example, the naturalvibration frequency of a vehicle traveling down a highway is oftenwithin the range of between about 40 hertz to 50 hertz. If the naturalfrequency of the mirror assembly is different than that of the vehicle,the mirror assembly will not vibrate in unison with the vehicle.Preferably, the mirror assembly has a higher frequency, such as at leastin the range of between about 50 hertz to 60 hertz, preferably greaterthan 60 hertz, more preferably greater than 80 hertz, and mostpreferably greater than 100 hertz. However, with the provision of adampener 636 in sleeve 631, vibration is reduced due to the inclusion ofthe vibration absorbing material.

Alternately, the stiffness of the rearview mirror support can beincreased thereby reducing vibration by including metal or other insertsmolded within the support sleeve. As shown in FIGS. 51, 52 and 53, amolded plastic rearview mirror support sleeve 640 similar to the supportsleeves described above, may include a metallic, cylindrical honeycombsleeve 642 insert molded centrally within the wall of the tube as shownin FIG. 51. In this example, honeycomb sleeve 642 has a lengthsufficient to extend from approximately the midpoint of socket 644 tothe midpoint of socket 646 along the central portion of sleeve 640.Alternately, insert 642 may be formed from magnesium, zinc, steel or thelike and may be solid or have an open, framework design. Molded ininserts such as the honeycomb insert 642 dampen the amplitude of thevibration of the sleeve. For a given frequency, reduction in theamplitude causes the vibration to be less noticeable. In addition, thesleeve itself may be formed from an engineered material such as mineralfilled resin, including mineral filled nylon having a filler of glass orcarbon.

An alternate form of the rearview mirror support sleeve is shown at 650in FIGS. 54-57. Like sleeve 640, sleeve 650 is a molded plastic tubewhich incorporates an insert 652 molded therein and formed from metallicor other rods having a generally cylindrical shape as shown in FIG. 57.Insert 652 may be made from steel, brass, aluminum, magnesium or zincand includes a plurality of longitudinally extending rods 654 securedsuch as by welding to annual rings 656 at opposite ends of the rods 654.Like the other sleeves described above, support 650 includes sockets658, 659 at opposite ends thereof for receipt of ball pivot members withan interference fit. Insert ring 656 at either end are positionedadjacent the ends of the sleeve outward of the sockets 658, 659 in orderto help retain ball pivot members within the sockets when fittedtherein.

With reference to FIGS. 58-61, yet another embodiment 670 of therearview mirror or vehicle accessory support sleeve of the presentinvention is shown. Sleeve 670 is preferably molded from a polymericmaterial such as those described above, including polybutyleneterepthalate (PBT), calcium carbonate polypropylene or polypropylene.Sleeve 670 is molded in one piece and includes a center section 672having a cylindrical outer surface, a windshield or channel mount end674 having a conical outer surface, and a tapered mirror assembly end676 also having a conical outer surface having a taper which is largerthan that for section 674. Conical, tapered end section 674 includesplurality of four axially extending slots 678 spaced equidistantlytherearound, while conical end 676 includes four equidistantly spacedslots 680. Just as in other embodiments of the support sleeve, slots678, 680 divide conical sections 674, 676 into segments or flanges whichcan individually flex and pivot to allow the compression fitting thereinof ball pivot members for an interference fit in sockets 682, 684,respectively. As in other sleeve embodiments, the inside diameter of theend openings 686, 688, are flared or tapered outwardly to facilitatecompression fitting of the ball pivot members within the sockets. Aswill be best seen in FIGS. 59-61, sleeve 670 includes an internalpassageway 689 extending between sockets 682, 684 having a varieddiameter which reduces from the size of the larger socket 682 to that ofthe smaller socket 684. Socket 682 is adapted to receive a larger pivotball member from a channel mount or header mount at the windshield endof the sleeve while smaller socket 684 is adapted to receive a smallerball pivot member projecting outwardly from the back of a rearviewmirror assembly. The larger size of socket 682, receiving thecorrespondingly larger sized ball pivot member, provides a greaterfrictional resistance to pivotal movement than does the smaller socket684, thereby allowing adjustment of the mirror assembly in socket 684without changing the position of the sleeve on the ball pivot memberreceived in the windshield end of the sleeve, and also enabling supportof heavier, more complex rearview mirror assemblies.

Any of the materials described above can be used for sleeve 670 which ispreferably molded in one piece. The continuous internal passageway 689allows the passage of electrical wiring therethrough as in otherembodiments of the sleeve for connection to electrical accessorieswithin the mirror assembly from the electrical wiring of the vehicle onwhich it is mounted. By changing the length of slots 678, 680, inaddition to selecting the material of the sleeve 670, the clamping forceon each of the pivot ball members received in sockets 682, 684 maybeadjusted as desired. The oversized central section 672 intermediateconical sections 674, 676 increases the overall stiffness of the sleeveto help reduce vibration amplitude and increase vibration performance.

As shown in FIG. 98, any of the above-described rearview mirror supportssuch as those of embodiments 10, 10′, 80, 110, 140, 142′, 600, 610,610′, 610″, 630, 640, 650 or 670 may include an integral wire-way orwiring conduit (such as an integral electrical wiring or cable housing)thereon as shown in embodiment 1000 of the rearview mirror support. Inthis version, embodiment 1000 includes a mirror support arm of the typedescribed above herein extending between a ball pivot joint 1002 at theinterior end 1004 (i.e. closest to windshield 1009) of a mirror mount1006 adapted to be removably mounted on mirror mounting button 1008 onthe interior surface of windshield 1009. The opposite end of mirrorsupport arm 1000 includes or receives a ball pivot member 1010 allowinga rearview mirror assembly 1012 similar to those described above to beadjustably mounted at the interior end of support arm 1000. Support arm1000 is preferably hollow and includes a pair of sockets at oppositeends as described above or, alternately, a socket and a formed ballmember thereon also as described above. In either case, the exteriorsurface of the support arm includes an elongated, hollow cable-way orhousing 1014 attached to the exterior of the support arm or integrallymolded therewith. As shown in FIG. 98, electrical wiring E from aconventional wire harness in a vehicle extends downwardly from the roofor header area at the top of the windshield to the position of themirror mount 1006 and along the exterior of the mirror mount to thelocation of an electrical connector 1016. A separate cable or electricalwire 1018 extends from an electronic circuit board within rearviewmirror assembly 1012 out of the rear of the mirror housing through thehollow cableway or housing 1014 to connector 1016 where it is joined tothe electrical system of the vehicle for operation of the electricalcircuit board 1022, electrochromic rearview mirror element 1024, and anyother electrical accessories within the mirror assembly. Alternately,wires E and 1018 could also extend through mount 1006 and/or pivotjoints 1002, 1010 as described above, as well as through housing 1014.Thus, housing 1014 shields, hides from view, protects and locates theelectrical wiring therewithin along the exterior of the mirror supportarm and provides a location for convenient connection to the electricalsystem of the vehicle.

As shown in FIG. 99, where like numerals indicate like parts to those inFIG. 98, a modified form of the mirror support arm 1000′ may alsoinclude an integral, hollow cable housing or cableway 1014′. In thisversion, mirror support arm 1000′ is of the type including ball pivotmembers 1002′ and 1010′ inserted within the opposing ends of the hollowtube forming the support arm, which tube ends are crimped or formed overagainst the ball members to retain them therein. A spring 1020 isincluded on the interior of the support arm between the ball pivotmembers to urge them outwardly against the crimped ends of the tube sothat the ball members will have a sufficient frictional resistance topivotal movement. Cable/wire housing 1014′ shields, guides and locatesthe electrical wiring extending therethrough in the same manner asdescribed above for housing 1014.

Note that the integral wire-way of the present invention (such ascable/wire housing 1014 or 1014′) can be, preferably, molded integrallywith the injection molding of a polymeric mirror support arm (or thehollow tube thereof). Optionally, this integral wire-way can be moldedof a different polymeric resin than that of the mirror support arm (suchas, for example, molding the wire-way housing from polypropylene resinand molding the support arm from acetal or filled-nylon, preferably in aco-injection molding operation). Also, the wire-way housing can includea flap element that comprises a living hinge, as known in the polymerdesign arts, allowing the integral cableway housing to be opened alongits length along the mirror support arm, and allowing the wiring/cablesto be inserted, and then closing the flap portion of the housing alongand around the wiring/cable (preferably, with a mechanical snap-closure,that is reopenable should it be desired to remove the wiring/cabling).

Alternately, a wiring/cabling receiving trough or recess can be moldedalong the length of a polymeric mirror support arm that is adapted toreceive wiring/cabling, and a separate cover element (preferably moldedof a thermoplastic polymer resin such as polypropylene or polyethylene)can be provided that attaches (such as by detachable snaps or similarmechanical fasteners) to the mirror support arm in order to furtherretain the wires/cables in the trough/recess, and to at leastsubstantially hide them from view.

Thus, and referring to FIG. 100 a mirror support arm 2000 of the typedescribed above herein extends between a ball pivot joint 2002 at theinterior end 2004 (i.e., closest to the windshield 2009) of a mirrormount 2006 adapted to be removably mounted on mirror mounting button2008 on the interior surface of windshield 2009. Support arm 2000typically will be solid and molded from resinous polymeric material. Theopposite end of mirror support arm 2000 includes or receives a ballpivot member 2010 allowing a rearview mirror assembly 2012 similar tothose described above to be adjustably mounted at the interior end ofsupport arm 2000. Support arm 2000 preferably includes a pair of socketsat opposite ends as described above, or alternately, a socket and aformed ball member thereon also as described above. In either case, theexterior surface of the support arm includes an elongated trough orrecess 2015 molded in support 2000, defined by side walls and a bottomsurface, and into which an electrical cable or wire 2018 is fitted. Anelongated, hollow cable-way, wire cover, or housing 2014 is removablyattached to the exterior of the support arm over recess 2015. Wire cover2014 includes a snap fastener 2011 on one edge extending along andattaching to one edge of recess 2015, and another snap fastener 2012 onits opposite edge extending along and attaching to the opposing edge ofrecess 2015. Cover 2014 may thus be snap fitted over recess 2015 afterwiring 2018 is placed in the trough and removed as desired for repairand the like. Alternately, cover 2014 may be pivotally attached overtrough 2015 such as by a living hinge as described above.

As also shown in FIG. 100, electrical wiring 2018 from a conventionalwire harness E in a vehicle extends downwardly from the roof or headerarea at the top of the windshield to the position of the mirror mount2006 and along the exterior of the mirror mount, into trough 2015, andinto the back of rearview mirror assembly 2012 through the hollowcableway or housing 2014 to a connector 2016 inside mirror assembly 2012for connection to electronic circuit board 2020, electrochromic rearviewmirror element 2022, and/or other electrical accessories. Housing 2014is fitted over recess 2015 and shields, hides from view, protects andlocates the electrical wiring therewithin along the exterior of themirror support arm, and may also provide a location for convenientconnection to the electrical system of the vehicle.

With reference to FIGS. 17 and 18, a plurality of rearview mirrorsupports such as those described above in embodiments 10, 10′, 80, 110,140, 142′, 600, 610, 610′, 610″, 630, 640, 650, 670, 1000, 1000′ or 2000may be used to support a rearview mirror assembly. As shown in FIG. 17,a modified rearview mirror assembly 82′ may include a pair ofhorizontally aligned, side-by-side molded polymeric sockets, each ofwhich is substantially similar to sockets 14, 16 described above.Sockets 160, 162 are each adapted to receive an annular spring membersuch as split ring 22 or 28 as shown in FIG. 18. Each socket 160, 162 isadapted to receive the ball pivot member 116 of a rearview mirrorsupport 110 therein after which split rings 22 or 28 are assembled overthe sockets to retain the ball members therein. Rearview mirror supports110 are then each secured to a suitable attachment member mountedside-by-side on an interior windshield surface for increased support ofthe rearview mirror assembly 82′ which may include a number ofelectrical or other added-feature components therein increasing itsweight over conventionally known rearview mirror assemblies. The dualsupport provided by the pair of rearview mirror supports 110 increasesvibration performance and stability of the overall assembly as comparedto single rearview mirror support assemblies.

As shown in FIG. 19, a further modified rearview mirror assembly 82″ maylikewise include a pair of rearview mirror supports 110 for supportingthe assembly on the interior surface of a windshield in the mannerdescribed above. However, in mirror assembly 82″, the sockets 160′, 162′are vertically aligned and positioned over and under one another on therear surface of the mirror housing. As in embodiment 82′, however, eachsocket is adapted to receive a rearview mirror support 110 in the mannerdescribed above for combined support of the overall assembly.

As shown in FIG. 20, a modified rearview mirror support 180 suitable foruse with the side-by-side sockets 160, 162 of rearview mirror assembly82′ in FIGS. 17 and 18 is illustrated. Support 180 is a rigid mirrorstay adapted to be secured to the header area of the interior of avehicle above the upper edge of the front windshield by a mountingrecess 183 in mounting section 182. Rigid support section 184 extendsdownwardly along the interior surface of the windshield and curvesrearwardly into the passenger compartment and diverges into a pair ofrearview mirror support arms 186, 188 positioned side-by-side with oneanother. Each support arm 186, 188 includes a socket 186 a, 188 a of thetype described above at 14, 16 and wherein rearview mirror assembly 82′would include outwardly projecting ball pivot members instead ofsockets. Alternately, arms 186, 188 could include ball pivot membersthereon in side-by-side position for insertion in sockets 160, 162 forappropriate pivotal adjustment. Mounting section 182 is suitable forreceipt of other accessories for use in the vehicles such as that shownin phantom at 189 representing a pod for mounting a clock or otherinstrument for viewing by the driver or other occupant of the vehiclepassenger compartment.

As shown in FIG. 21, a further embodiment 190 of a mirror stay forsupporting a rearview mirror assembly such as that shown at 82′ or 82″is illustrated. Mirror support or stay 190 includes three support armsor sleeves 192, 194 and 196 which are rigidly joined together byconnecting arms 198, 200. Arms 192, 194 are substantially similar inlength, while arm 196 is shorter than arms 192, 194. At the forward endof each arm 192, 194, 196 is either a socket 192 a, 194 a, 196 a or aball pivot member for attachment to the rear surface of a rearviewmirror assembly such as that shown at 82, 82′ or 82″ for proper pivotaladjustment with increased stability and vibrational support. Theopposite ends of each of the arms 192, 194 include sockets for receiptof ball pivot members from two separate mounting members or channelmounts such as that shown at 18 adapted to be secured to the interiorsurface of a windshield. Accordingly, the present invention encompassesthe support of a rearview mirror assembly by one or a plurality ofrearview mirror supports for increased vibration performance andstability.

With reference to FIGS. 62-72, a further embodiment 700 of a moldedplastic mirror stay adapted for slidable mounting on a conventional,windshield mounted attachment member or button and incorporating asocket for receiving a compression fitted, interference mounted ballpivot member from a rearview mirror or other vehicular accessory isillustrated. Mirror stay 700 is preferably molded in one piece from aresinous, polymeric material such as acetal, nylon or a similarengineering polymer, and includes a body 702 having a top surface 704,side surfaces 706, 708, a rear surface 710 facing the interior of thevehicle on which the stay 700 is mounted, a bottom surface 711, and aconical, tapered socket portion 712 adapted to receive a ball pivotmember therein via compression or press fitting.

On the forward facing or non-exposed surface intermediate the topsurface 704 and sides 706, 708 is a breakaway type, mounting portion 714adapted to slidably receive a windshield attachment member or button. Asis best seen in FIGS. 63 and 65-69, mounting portion or area 714includes a pair of spaced, opposed side flanges 716, 718 having inclinedwindshield button engaging surfaces 720, 722. As shown in FIG. 65,flanges 716, 718 taper toward one another in the direction toward topsurface 704 while inclined button engaging surfaces 720, 722 tapertoward one another as they extend toward the opening therebetween asshown in FIG. 69. The result is a button receiving pocket having adouble tapered configuration for tightly and securely receiving thedouble tapered, wedge shaped windshield button B in a wedge type,interference fit. In order to securely retain the stay 700 on button Bwhen mounted, stay 700 also includes a latch beam member 724 providingan installation tab which extends in cantilevered fashion from the topend 704 of stay 700 downwardly in a direction generally parallel to theoutwardly facing rear surface 710 but spaced therefrom as shown in FIGS.66 and 67. Latch member 724 includes a thicker body portion 726 forproviding rigidity and strength which extends into a thinner buttonengaging securing portion 728 terminating in a shoulder or ledge 730which engages the bottom end of the windshield button B when fullyreceived in the stay. The lower edge of latch member 724 includes aninclined surface 732 for engaging and camming latch member 724 towardrear wall 710 during installation. At the opposite end of latch member724, a top wall 734 defines a stop preventing the stay from slidingdownwardly off the windshield button. The exposed surface of latchmember 724 includes a pair of surfaces 736, 738 which are non-parallelto one another and extend at a slight angle toward apex 740 for engagingand applying a force normal to the engaged surface of the windshieldbutton for secure retention of the button therein. As such, latch member724 acts as a cantilever type leaf spring firmly holding the buttontherein between inclined surfaces 720, 722.

Stay 700 also includes a pair of slots 742, 744 in top surface 704adjacent top wall 734 which enables flanges 716, 718 to flex away fromwindshield button B upon the application of sufficient force such thatthe stay will break away and fall from windshield button B upon impactsuch as during an accident to facilitate injury prevention.

Alternate forms of the breakaway side flanges are shown in FIGS. 70-72.In FIG. 70, side flanges 716 a, 718 a are formed to include flexibilityenhancing elements such as recesses or notches 746, 748 which allow thesides flanges to flex away from the latch member 724 at specifiedconditions of force input upon impact. Alternately, as shown in FIG. 71,side flanges 716 b, 718 b may include outer notches 750, 752 providingthe side flanges with the ability to flex and allow breakaway actionfrom the windshield button upon specified conditions of force input.Finally, as another alternative in FIG. 72, side flanges 716 c, 718 cmay include notched outer walls having notches 754, 756 allowing thewalls or flanges to flex for breakaway action as described above.

In any of the versions of stay 700 described above, a tapered, conicalball member receiving socket 712 is provided including tapered, conicalouter surface 758 and an inner passageway 760 which extends entirelythrough stay 700 to allow the passage of electrical wires or the like tothe rearview mirror assembly from the vehicle electrical system. Formednear the outer end of passage 760 is an annular ball socket 762 (FIG.66) which extends continuously around the interior of four cantileveredball member engaging flanges or prongs 764. Flanges 764 are defined byaxially extending slots 766 at four places, the slots extendinggenerally parallel to the axis of passageway 760. The flanges 764provide a normal force for friction on the ball pivot member when snapfitted or press fitted therein. The length of the slots can be changedand defined to provide a desired clamping force, the force decreasing asthe length of the slots increases. Further, socket 762 is undercut toprovide positive engagement of the ball member in the socket during snapin assembly and to prevent pull out.

As shown in FIGS. 73-77, an alternate embodiment 780 of a molded plasticmirror stay including a molded socket for receiving a pivot ball memberfrom a rearview mirror assembly is shown. Stay 780 is adapted formounting to the header portion or interior roof of a vehicle typicallyadjacent the upper edge of the windshield and is preferably molded inone piece from a resinous, polymeric material such as acetal, glassand/or mineral-filled nylon, filled polypropylene or a similarengineering polymer of a desired color, and includes a header mountingportion 782, an elongated curved support shaft 784 and a socket portion786 formed at the free end of the shaft portion. Mounting portion 782includes an elongated body 788 including a plurality of mountingapertures 790 and a pair of opposed, side recesses 792 adapted toreceive spring mounting clips from a mounting bracket secured to theheader or roof portion of a vehicle generally above the windshield area.Shaft 784 extends in one piece from the lower edge of mounting body 788and curves downwardly to a position from which socket portion 786extends downwardly, preferably at an angle of approximately 100 to 150degrees to mounting body 788. Socket portion 786 includes a socket 794formed integrally therein to receive a pivot ball member from the rear,larger side of the socket over which a spring or other retainer membermay be mounted.

In order to reduce vibration and provide sufficient support andstiffness for the stay 780, a metallic or other rigid insert 796 (FIG.77) may be integrally molded within the body of the stay 780 as shown inFIG. 76 such that it extends from header mounting portion 782 throughthe center of shaft 784 to the position of socket portion 786. Insert796 includes an enlarged portion 798 received in header mounting portion782 and shaft reinforcing portion 799 received in shaft 784.Accordingly, reinforcing member 796 provides stiffness and strength forstay 780 when it is mounted to the header above a windshield such thatshaft curves downwardly along the inside surface of the windshield to aposition from which a rearview mirror or other vehicle accessory may besupported via a ball pivot member received in socket portion 786 therebyreducing vibration and providing a more stable support for the mirrorassembly.

An alternate embodiment 800 of the mirror stay of the present inventionis shown in FIGS. 78-82. Mirror stay 800, like mirror stays 700 and 780is preferably molded in one piece from a resinous, polymeric materialsuch as acetal, glass and/or mineral-filled nylon, filled polypropyleneor a similar engineering polymer, and includes a body portion 802 havinga top end 804 adjacent a mounting portion 806. Body 802 curvesdownwardly to a bottom 808 adjacent a ball member support area 810 fromwhich molded pivot ball member 812 extends rearwardly into the passengercompartment of the vehicle when the stay is mounted on or adjacent avehicle windshield. Body portion 802 also includes sides 814, 816 which,together with top 804 and bottom 808 define a hollow interior whichextends forwardly toward the windshield of the vehicle and in whichreinforcing ribs 818 are integrally molded for stiffness and support.Within the hollow interior adjacent top 804 and intermediate sides 814,816 are a series of molded resilient, flexible flanges 820 forming amount adapted to be secured in a corresponding bracket or mount securedto the vehicle adjacent the windshield. Mounting flanges 820 are of thetype shown and described in (insert reference to prior Donnelly or DMLpatent or application), the description of which is hereby incorporatedby reference herein. As is best seen in FIGS. 79, 81 and 82, ball member812 extends rearwardly from section 810 into the passenger compartmentof the vehicle and includes a spherical ball pivot member spacedoutwardly from the body of the mirror stay by neck 822. Accordingly,when mounted on or adjacent the windshield, stay 800 extends downwardlyalong the windshield and provides ball member 812 in position forreceipt in a corresponding socket of a rearview mirror assembly toprovide adjustment of the mirror assembly for use by the driver of thevehicle. As shown in FIGS. 78 and 81, a passageway 824 may be providedthrough ball member 812 and neck 822 into the hollow interior of themirror stay for receipt of electrical wires from the vehicle electricalsystem leading into the rearview mirror assembly for electricalaccessories mounted therein.

As shown in FIGS. 22-24, another form of rearview mirror housing 210 isshown of the type useful with the rearview mirror supports of thepresent invention as described above. Rearview mirror housing 210 ismolded from a resinous plastic material of a desired color such as nylon(glass-filled or unfilled), ABS plastic, or polypropylene (glass-filledor unfilled) and includes a rear housing member 212 and a front bezel orrim 214 adapted to retain a prismatic or other reflective mirror elementtherein and a day/night toggle actuator, or alternately anelectrochromic reflective mirror element when assembled. Mirror housing210 is adapted to support a four microphone sensor array in which fourmicrophone sensors 216, 218, 220 and 222 are supported within the rearhousing portion adjacent the bottom wall of the housing to which accessis provided by acoustic porting formed in the mirror housing itself.Specifically, microphone 216 is acoustically accessed through a frontacoustic port 216 a molded through the front surface of bezel/rim 214and a rear acoustic port 216 b molded through either the bottom wall ofrear housing portion 212 or the bottom wall of bezel 214 or acombination thereof. Hence, rearview mirror housing 210 is provided witha pair of acoustic ports through which sound waves may pass for eachmicrophone sensor mounted within the assembly via porting which isintegrally formed upon molding of the mirror housing. Suitablemicrophone/sound processing systems which may be used with housing 210include commonly owned, copending, U.S. patents or patent applicationsSer. No. 09/382,720, filed Aug. 25, 1999, entitled ACCESSORY MODULE FORVEHICLE, now U.S. Pat. No. 6,243,003; Ser. No. 09/396,179, filed Sep.14, 1999, entitled INDICATOR FOR VEHICLE ACCESSORY, now U.S. Pat. No.6,278,377; and Ser. No. 09/466,010, filed Dec. 17, 1999, entitledINTERIOR REARVIEW MIRROR SOUND PROCESSING SYSTEM, now U.S. Pat. No.6,420,975, the disclosures of which are hereby incorporated by referenceherein.

As will be understood, a wide variety of other rearview mirrorassemblies incorporating a wide range of prismatic and electro-opticreflective mirror elements and other electrical components, instrumentsand displays may be supported with the supports of the presentinvention. Exemplary is that shown in U.S. patent application Ser. No.09/244,726, filed Feb. 5, 1999, entitled REARVIEW MIRROR ASSEMBLYINCORPORATING INFORMATION DISPLAY, now U.S. Pat. No. 6,172,613, thedisclosure of which is hereby incorporated by reference herein. Suchrearview mirror assemblies are often heavier than prior assemblies andbenefit from the increased stability and vibration performance providedby the support of the present invention.

Referring now to FIGS. 25-25D, a first embodiment 240 of a vehicleaccessory mounting member or channel mount is shown which is adapted tosupport any one of the rearview mirror supports described above.Mounting member 240 may be formed from metal such as die cast zinc orsintered metal, but preferably is molded from a polymeric resinousmaterial of a desired color such as an engineering plastic includingnylon (glass-filled or unfilled), ABS plastic, or polypropylene(glass-filled or unfilled). As above, mounting member 240 may be colormatched to one or more of the other components of the rearview mirrorassembly. Mounting member 240 is adapted to slidably engage anattachment member or windshield button of the conventional wedge-shaped,double tapered type such as that shown in FIGS. 44 and 44A, or any ofthose set forth in FIGS. 30-43A or 45 and 45A herein. Mounting member240 includes a mounting body 242 having an overall wedge shape andincluding a top end 244, bottom end 246, and opposing sides 248, 250. Onthe front surface 252, a mounting arm 254 is centrally located at aposition approximately one-half of the distance between top end 244 andbottom 246 such that it is generally centered with respect to theposition of a windshield mount attaching member B when received betweenshoulders 260, 262 on rear surface 258 as described below, and extendsoutwardly at an acute angle to top end 244, projects upwardly away frombottom end 246 and terminates in a spherically-shaped ball pivot member256. Ball pivot member 256 may be oversized as compared to conventionalball pivot members in rearview mirror supports to provide a largersurface area engaging a corresponding socket for increased frictionalresistance to pivoting and thus enable support of heavier and/or largerrearview mirror assemblies. For example, the diameter of an oversizedball pivot member 256 is at least approximately 15.34 millimeters (mm).

At the outer edges of generally planar rear surface 258 are a pair ofintegral elongated shoulders or receiving members 260, 262 which arejoined at their upper ends by top shoulder 264 forming a generallyU-shaped wall around the periphery of the rear surface 258. Receivingmembers 260, 262 include slide surfaces 265, 266 adapted to engage theouter edges of the windshield mounted attaching member or button B suchas that shown in FIGS. 25D, 44 and 44A. Surfaces 265, 266 arenon-parallel, extend away from one another, and are spaced closestadjacent top end 244 of the mounting member and spaced farthest at thebottom, terminal ends of receiving members 260, 262 adjacent bottom end246. In addition, surfaces 265, 266 are inclined inwardly toward oneanother such that a pocket or space adjacent rear surface 258 is formedhaving a double tapered shape as shown in FIGS. 25B and 25D. A screwreceiving aperture 268 extends from front surface 252 through mountingmember 242 and opens at rear surface 258 to receive a set screw orretainer 270 to securely attach and retain mounting member 240 to buttonB when slidably mounted thereon. Screw receiving aperture 268 ispositioned between the lower periphery of support arm 254 and bottomsurface 246 and is closer to that bottom surface than screw apertures inconventionally known mounting members. The positioning of support arm254 at the central position of front surface 252 and generally centeredwith respect to windshield mounted attaching member B on the rearsurface 258 and farther from top end 244 than in conventionally knownmounting members provides more secure attachment of the rearview mirrorsupport to the windshield surface by reducing the tensile force impartedat the top or uppermost portion of the windshield button B therebyreducing the stress on the adhesive relied upon to secure the attachmentmember or button to the windshield surface. In addition, the positioningof set screw 270 closer to the bottom end 246 provides more secureattachment to the windshield button by preventing rocking motion ofmember 240 on the attachment member. Member 240 is assembled on thewindshield button by positioning the rear surface 258 adjacent the topend of the wedge-shaped button B with its edges adjacent slide surfaces264, 266, and sliding the mounting member downwardly over the buttonafter it is attached to the windshield surface until it is firmly seatedbetween receiving members 260, 262 in the manner shown in FIG. 25B.Thereafter, set screw 270 is tightened to secure and retain the mountingmember in place.

As shown in FIGS. 26-26D, a second embodiment 275 of the vehicleaccessory mounting member of the present invention is illustrated. Likemounting member 240, member 275 includes a metal or plastic mountingbody 276 having a top end 278, bottom end 280, opposing sides 282, 284and front surface 286 from which mounting arm 288 extends from acentrally located position at an upward angle terminating in sphericalball pivot member 290. As above, ball pivot member 290 is preferablyoversized for enhanced frictional resistance to movement of a supportincluding a corresponding socket. A U-shaped, upstanding wall 292extends around the periphery of generally planar rear surface 294opening adjacent bottom end 280. Instead of non-parallel, inwardlytapered slide surfaces on a wall 290 as in mounting member 240, member275 includes a pair of non-parallel, elongated slots 296, 298 whichreceive elongated spring members 300, 302. Slots 296, 298 have their topends which are adjacent top end 278 closer than their bottom ends whichare adjacent bottom end 280. In addition, as will be seen from FIGS. 26Band 26D, the inside surfaces of the spring members which projectoutwardly beyond rear surface 294 define slide surfaces 300 a, 302 awhich extend inwardly toward one another to form a tapered pocket whichreceives the correspondingly tapered side surfaces of a wedge-shapedattaching member or windshield button B in the same manner as describedabove for embodiment 240. In addition, however, the resiliency of thespring members 300, 302 allows them to flex outwardly while beingretained in slots 296, 298 by inwardly extending upper flanges 300 b,302 b to resiliently and firmly engage the opposing side surfaces of theattachment member on the windshield. When the rearview mirror support ormounting member 275 is impacted, however, the resiliency of springmembers 300, 302 allows the entire mounting member and supportedrearview mirror to release and break away from the windshield mountedbutton to prevent injury.

With reference to FIGS. 26E and 26F, a modified, third embodiment 275′of the vehicle accessory mounting member of the present invention isshown. Like mounting member 275, mounting member 275′ includes a metalor plastic mounting body 276′, top end 278′, bottom end 280′, opposingsides 282′ and 284′, and front surface 286′ from which mounting arm 288′extends from a centrally located position at an upward angle terminatingin spherical ball pivot member 290′ which is preferably oversized asdescribed above. A U-shaped, upstanding wall 295′ extends around theperiphery of a generally planar rear surface 294′ opening adjacentbottom end 280. A pair of non-parallel, elongated slots 296′, 298′ areincluded which receive a one-piece, elongated spring member 300′ havinga back member 301 and upstanding spring flanges 303, 305 which projectthrough slots 296′, 298′. Like spring members 300, 302 in embodiment275, the inside surfaces of spring members 303, 305 which projectoutwardly beyond rear surface 294′ define slide surfaces 303 a, 305 awhich extend inwardly toward one another to form a tapered pocket whichreceives the correspondingly tapered side surfaces of a wedge shapedattaching member or windshield button B in the same manner as describedabove for embodiments 240 and 275. In addition, the resiliency of springmembers 303, 305 allows them to flex outwardly while being retained inslots 296′, 298′ by means of back member 301 to resiliently and firmlyengage the opposing side surfaces of the attachment member on thewindshield. In addition, mounting member 275 includes a mirror reflectorvibration reducing/dampening element such as a thin foam, rubber orother resilient pad 306 or layer which covers at least a portion of (andpreferably substantially the entirety of) the planar surface 294′ andforms a cushion between the windshield attachment member or button andthe surface 294′ when the mount 275′ is mounted on the windshieldbutton. Pad 306 is preferably adhered to surface 294′ with a suitableadhesive and serves to cushion contact with the windshield button anddampen any vibration which might be transmitted therethrough.Alternately, pad 306 may be formed integrally with mirror mount 275 inthe event the mount is injection molded, the cushioning pad beingco-injected from a softer material adapted to dampen vibration betweenthe mirror mount and the windshield button.

A fourth embodiment 310 of the vehicle accessory-mounting member of thepresent invention is shown in FIGS. 27 and 27A. Mounting member 310includes mounting body 312 having top end 314, bottom end 316, opposingsides 318, 320 and a U-shaped, upstanding wall 322 extending around theperiphery of generally planar rear surface 324. A mounting arm 328extends upwardly at an angle from the center position of front surface326 in the same manner as support arms 254 and 288 of mounting members240 and 275. Mounting arm 328 terminates in a spherical ball pivotmember 330 for receipt in a rearview mirror support as described above.As above, ball pivot member 330 may be oversized or conventionallysized. Mounting member 310 is retained on a wedge-shaped, double taperedattaching member or windshield button B (FIGS. 44, 44A) by a pair ofU-shaped spring bands 332, 334 which are recessed within front surface326 and extend around sides 318, 320, each spring band includes a pairof free end edges 332 a, 332 b and 334 a, 334 b which project outwardlyfrom rear surface 324 through openings in peripheral wall 320. Theinside surfaces 333, 335 of these free ends define slide surfacesadapted to resiliently engage the opposing, tapered side surfaces of awedge-shaped attaching member or windshield button B (FIGS. 44, 44A) inthe same manner as surfaces 300 a, 302 a. When member 310, or therearview mirror support or rearview mirror assembly supported thereby,is impacted, the resiliency of spring bands 332, 334 allows those freeends 332 a, 332 b, 334 a, 334 b and slide surfaces 333, 335 to releaseand break away from the attaching member to prevent injury.

Referring now to FIGS. 28-28E, a fifth embodiment 340 of the vehicleaccessory mounting member of the present invention is illustrated.Mounting member 340 includes a mounting body 342 again formed from diecast or sintered metal or molded polymeric resinous material andincludes a top end 344, bottom end 346, opposing sides 348, 350, and acontoured, raised front surface from which mounting arm 354 extends atan upward angle from a centrally located position midway between the topand bottom ends and terminates in a spherical ball pivot member 356which may be oversized as desired. A pair of non-parallel, elongatedshoulders or receiving members 360, 362 extend outwardly away from oneanother toward the bottom end 346 in the same manner as for mountingmember 240, and define slide surfaces 364, 366 for receiving awedge-shaped windshield button B as shown in FIGS. 28D and 28E. Slidesurfaces 364, 366 are tapered inwardly toward one another and furtherinclude reduced thickness areas 368, 370 providing frangible portionsadapted to fracture upon application of a sufficient force to themounting member or rearview mirror assembly such that the mountingmember will be released from the windshield mounted attachment member orbutton upon fracture of the shoulders or receiving members 360, 362. Afastener receiving aperture 372 extends through the body 342 from frontsurface 352 to the rear surface 358 to receive a fastener such as a setscrew adjacent the bottom end of the mounting member for secureretention of the mounting member on the attachment member until fractureof receiving members 360, 362 occurs upon impact. As shown in FIGS. 28and 28B openings 374 are provided through top end 344 such thatelectrical conductors or wires may be received therethrough for passagethrough the mounting member, a rearview mirror support mounted thereon,and into the supported rearview assembly as described above.

With reference to FIGS. 83-85, a sixth embodiment 850 of the vehicleaccessory mounting member of the present invention is shown. Mountingmember 850 is similar to mounting member 340 except that it ispreferably molded in one piece from a resinous, polymeric material suchas acetal, glass and/or mineral-filled nylon, filled polypropylene or asimilar engineering polymer but does not include frangible side surfaceswhich breakaway to release the mount from the windshield button uponimpact. Mount 850 includes molded body 852 including a top end 854,bottom end 855, opposing sides 856, 858, and a contoured, raised frontsurface from which mounting arm 860 extends at an upward angle from acentrally located position midway between the top and bottom ends. Arm860 terminates in a spherical ball member 862 which may be oversized asdescribed above. A pair of nonparallel, elongated shoulders or receivingmembers 864, 866 extend outwardly away from one another toward thebottom end 888 in the same manner as for mounting member 340 and defineinwardly tapered slide surfaces for receiving a wedge shaped windshieldbutton in the same manner as for embodiment 340. In order to strengthenand stiffen the mounting member 850, a formed, sheet metal insert 868(FIG. 85) is insert molded within the mounting member 850 as shown inFIG. 84. Insert 868 includes a body portion 870, downwardly extendingside flanges 872, 874, and an upstanding central flange 876. dimples ordepressions 878 are in various portions of the insert body to provideareas into which the moldable material for mounting member 850 can flowto properly imbed the insert therewithin. An aperture 880 from whichflange 876 is bent serves the same purpose. A fastener or screwreceiving aperture 882 extends through body 852 and insert 868 ataperture 879 as shown in FIG. 84 to receive a fastener such as a setscrew to prevent removal of the mounting member when the mounting memberis slidably mounted on a wedge shaped windshield button.

A modified seventh form 850′ of the molded vehicle accessory mountingmember or channel mount of the present invention is shown in FIGS.86-89. Mounting member 850′ is similar to mount 850 except that mountingarm 860′ terminating in a preferably oversized spherical ball pivotmember 862′ extends at an upward angle from a position on mount body852′ which is adjacent the top end 854′ of the mount. In addition, theinsert 868′ includes an upwardly extending flange 876′ which reinforcesthe mounting arm 860′ but extends from the top end of the insert.Further, insert 868′ includes depressions or recessed areas 878′ inupstanding flange 876′ and apertures 879′ for proper retention of theinsert when molded within the mirror mount. A fastener or screwreceiving aperture 852′ extends through body 852′.

Referring now to FIGS. 29-29H, an eighth embodiment 380 of the vehicleaccessory mounting member or channel mount of the present invention isshown. Mounting member 380 includes a mounting body 382 having a top end384, bottom end 386, opposing sides 388, 390, front surface 392 andgenerally planar rear surface 394. Rear surface 394 is recessed todefine an upstanding, U-shaped peripheral wall 396 which opens adjacentbottom end 386. The internal surfaces of opposing side portions of sidewalls 396 are formed with a pair of parallel, recessed channels 397separated by an elongated ridge 399. At the upper-end of rear surface394, adjacent top end 384 is an inclined projection 398 adapted toreceive and secure spring member 410 as described below. As with theother embodiments of the accessory mounting member, a mounting arm 400is formed integrally with body 382 and extends outwardly and upwardlyfrom a centered position on front surface 392 terminating in a sphericalball pivot member 402 which may be oversized or conventionally sized asabove.

Received within the upstanding wall 396 on rear surface 394 is aone-piece spring member 410 best seen in FIGS. 29B, D, E and I. Springmember 410 is formed from resilient metal such as spring steel andincludes a generally planar base 412, a pair of upstanding side flanges414, 416 adapted to receive a windshield mounting button therebetweenand a front or upper flange 418. The configuration of channels 397 andridge 399 on wall 396 is adapted to correspond to the shape of sideflanges 414, 416 which are bent inwardly and upwardly to define slidesurfaces 414 a, 416 a which receive the windshield attachment member.Slide surfaces 414 a, 416 a are inwardly tapered toward one another andare non-parallel to one another being closer together at the endadjacent front flange 418 than at the opposite end which is adapted tobe adjacent bottom end 386 when spring member 410 is mounted in body382. At the rear end of each of the side flanges 414, 416 in alignmentwith slide surfaces 414 a, 416 a is an inwardly extending rear flange420, 422 which helps to confine the windshield mounting button withinthe spring member when mounted. In addition, base 412 includes anelongated aperture 424 adapted to be received over projection 398 uponinstallation of spring member 410 in body 382.

Accordingly, when mounted over an attachment member or windshield buttonB as shown in FIG. 29H, the inclined side surfaces of the attachmentmember engage slide surfaces 414 a, 416 a and the rearmost inner edgesof rear flanges 420, 422 as the mounting member is slid downwardly overthe windshield attachment member. As formed, front flange 418 of springmember 410 is bent upwardly intermediate side flanges 414, 416 as shownin FIGS. 29D, 29E and 29G. However, when the top end of the windshieldattachment member or button engages front flange 418 with sufficientforce upon sliding insertion, flange 418 is flexed forwardly until it nolonger separates side flanges 414, 416 and slide surfaces 414 a, 416 aresiliently snap inwardly against the inwardly tapered sides ofwindshield attachment member B as shown in FIG. 29H. In such position,rear flanges 420, 422 confine the button within the spring member andprevent the mounting member and spring member combination from “walkingoff” the button during use. When slide surfaces 414 a, 416 a flexinwardly against the sides of the attachment member, an audible click orverification is heard indicating to the installer that installation iscomplete.

FIG. 90 illustrates a modified ninth form 380′ similar to mountingmember 380 except that one piece spring member 410′ includes a pair ofapertures 430 instead of one elongated aperture 424. Mounting body 382′of mounting member 380′ is adapted to be molded in one piece from aresinous polymeric material such as acetal, glass and/or mineral fillednylon, filled polypropylene or a similar engineering material with onepiece spring member 410′ insert molded therewithin such that the moldingmaterial flows through apertures 430 to encase the generally planar base412′ of the spring member and retain the spring in position generally asdescribed above for embodiment 380. A windshield button B may then beslidably received within the spring member in the same manner asdescribed above for embodiment 380.

A tenth embodiment 900 of the vehicle accessory mounting member orchannel mount of the present invention is shown in FIGS. 91-94. Mountingmember 900 includes a body portion 902 preferably molded in one piecefrom a resinous, polymeric material such as acetal, glass and/ormineral-filled nylon, filled polypropylene or a similar engineeringpolymer, or formed from sintered metal or the like and includes a topend 904, bottom end 906, opposing sides 908, 910 and a contoured, raisedfront surface from which mounting arm 912 extends at an upward angleadjacent top end 904. Mounting arm 912 terminates in a spherical ballpivot member 914 which may be oversized if desired as described above. Apair of nonparallel, elongated shoulders or receiving members 916, 918extend outwardly away from one another toward the bottom end 906 in thesame manner as described above for mounting members 240, 340, 850 and850′, and define slide surfaces 920, 922 for receiving a wedge shapedwindshield button B in the manner described above. Slide surfaces 920,922 are tapered inwardly toward one another and further include reducedthickness areas 921, 923 providing frangible portions adapted tofracture upon application of a sufficient force to the mounting memberor rearview mirror assembly such that the mounting member will bereleased from the windshield mounted attachment member or button uponfracture of the shoulders or receiving members 916, 918. Instead of aset screw receiving aperture extending through body 902 for retention ofthe mounting member on the windshield button, mounting member 900includes a lever 924 also preferably molded from a resinous plasticmaterial and pivotally mounted within an aperture 926 extending throughthe central portion of the body 902. Lever 924 includes an engagingflange 928 extending at an acute angle to an operating flange 930 and anenlarged finger engaging portion 932 at the terminal end of flange 930.A pair of parallel, stub axles 934 extend in opposite directions fromeither side of the lever at the junction of flanges 928, 930 for receiptin pockets formed within aperture 926 to pivotally mount the levertherein as shown in FIG. 93.

In operation, when mount 900 is slidably received over a windshieldbutton via shoulders 916, 918, and the windshield button is fullyreceived within the mirror mount, pivotal lever 924 is pivoted viaflange 930 and engaging portion 932 from the position shown in phantomin FIG. 92 to that shown in solid in FIGS. 92 and 93. In such position,engaging flange 928 which has a length slightly greater than thethickness of body 902 at that point engages the outer surface of thewindshield button to frictionally engage the button surface and retainthe button within flanges 916, 918 and prevent the mirror mount frombeing slidably removed from the windshield button. In the event themirror mount receives a sufficient force or impact, the frangibleshoulders 916, 918 will fracture allowing release of the mounting memberfrom the windshield button. Lever 924, thus, eliminates the need for aseparate retaining screw.

Referring now to FIGS. 30-43A, various embodiments of a windshieldmounted attachment member are shown to which the vehicle accessorymounting members and rearview mirror supports described above areassembled for supporting interior rearview mirror assemblies incantilevered fashion from the interior windshield surface of a vehicle.Each of these attachment members is adapted to provide an increasedadhesive securing area for attachment to the windshield surface in orderto support the heavier weights of more modem, multi component rearviewmirror assemblies. These increased sized attachment members providelarger, wider and more effective support areas which more effectivelyresist the tensile peeling force applied to the attachment member fromthe rearview mirror support and mirror assemblies.

As shown in FIGS. 30 and 30A, a first embodiment 450 of the attachmentmember includes a circular base member 452 through which a plurality ofapertures 454 are formed in order to reduce the overall weight of theattachment member. Centered on one side of circular base member 452 isan upstanding circular projection having a diameter less than thediameter of circular base 452. Projection 456 can be secured to base 452by welding or the like or the entire attachment member can be sinteredor formed from powdered metal or die cast from material such as zinc inone piece.

A modified embodiment 450′ of attachment member 450 is shown in FIGS. 31and 31A wherein base member 452′ includes a central aperture 455 inaddition to apertures 454 as in member 450. A circular projection 456 iscentered on and secured to base member 452′.

With reference to FIGS. 32 and 32A, another form 460 of the attachmentmember is shown including a general keyhole shape having a generallycircular base 462 having a rectangular flange projection 464 from itstop circumferential portion extending outwardly therefrom. Flange 464 isadapted to extend upwardly when the attachment member is secured to thewindshield surface by a suitable adhesive. As in prior embodiments, acircular projection 466 can be welded to the top surface of base 462 orthe entire attachment member can be sintered or otherwise formed frommetal in one piece.

In FIGS. 33 and 33A, embodiment 470 of the attachment member is similarto embodiment 460 and includes a base 462′ having a wider flange 464′formed thereon. Overall, base 464′ of member 470 has the shape of arectangle with one end rounded.

In FIGS. 34 and 34A, embodiment 480 of the attachment member is similarto embodiments 450 and 450′ except that circular base member 482 towhich circular projection 484 is secured does not include any weightreducing apertures therethrough.

With reference to FIGS. 35-37A, embodiments 490, 500 and 510 of theattachment members each include an enlarged base 492, 502, 512 of anirregular shape to which a circular projecting member 494, 504, 514 issecured on one surface. Specifically, base member 492 has the shape ofan elongated, truncated triangle, while base members 502 and 512 havethe shape of a triangle with their apexes rounded. In addition, circularprojecting member 514 has a diameter smaller than the width of base 512while projecting members 494 and 504 have a diameter larger than thewidth of their respective base members.

In FIGS. 38-41A, the attachment members include base members formed inthe shape of a T, cross, X or X with an additional cross member. Thus,in embodiment 520, base member 522 is in the shape of a T to whichcircular projecting member 524 is secured on one surface.

In embodiment 530, base member 532 is in the shape of a cross withcircular projecting member 534 secured on one surface thereof.

In embodiment 540, base member 542 is in the shape of a cross with anadditional leg member 544 to which circular projecting member 546 issecured on one surface.

In embodiment 550, base member 552 is in the shape of an X to whichcircular projecting member 554 is secured on one surface.

In embodiment 560, base member 562 is in the shape of a rectangle towhich a circular projecting member 564 having a diameter equivalent tothe width of the rectangle is secured.

In embodiment 570, in FIGS. 43 and 43A, base member 572 is generallycircular but includes a pair of diametrically opposed rectangularflanges 574 extending outwardly therefrom. A circular projection 576having a diameter less than the diameter of the main portion of base 572is secured to one side.

In each of the above embodiments 450-570 of the attachment member, inplace of the circular projection to which a vehicle accessory mountingmember is adapted to be secured, a wedge-shaped, double tapered mountingbody such as that shown in FIGS. 44 and 44A may be secured in place ofthe circular projection. Such wedge-shaped mounting member B is of thetype described above in connection with the various embodiments of thevehicle accessory mounting members and has non-parallel sides which areinwardly tapered to retain the mounting members thereon. Similarly, asshown in FIGS. 45 and 45A, a polygonal, preferably hexagonal projectionC may also be substituted in place of the circular projections orwedge-shaped double tapered mounting projection B.

Referring now to FIGS. 95-97, one form 950 of a suitable electricalswitch of the type which may be used in rearview mirror assembly such asthat described above at 80 is shown. Switch 950 includes a lightemitting diode (LED) integrated into the actuator/plunger of the switchto illuminate indicia and indicate the switch function on the switchactuator or plunger as described below. Switch 950 is of the type knownas a circular dome or tactile dome switch with an integrated LED.

As shown in FIGS. 95 and 96, switch 950 includes a slidable plunger 952received through aperture 954 in a rectangular or square switch housing956. Plunger 952 includes an LED indicator on its upper end whichindicates the function of the switch when mounted in a rearview mirrorassembly. Plunger 952 is adapted to be engaged by the finger of anoperator to depress or move the switch plunger to operate the switch.Switch plunger 952 is generally cylindrical in shape and is adapted toslide axially in circular aperture 954 into and out of the switchhousing 956. Switch housing 956 includes electrical contacts 960 whichare connected through appropriate bus bars to the slidable plunger 952as is explained more fully below.

As shown in FIG. 97, the LED indicator 958 includes a housing 962adapted to be received on and connect to plunger 952. A suitable LED 964(such as are disclosed in U.S. application Ser. No. 09/793,002, filedFeb. 26, 2001, entitled VIDEO MIRROR SYSTEM INCORPORATING AN ACCESSORYMODULE, now U.S. Pat. No. 6,690,268, and U.S. Provisional PatentApplication Ser. No. 60/315,384, filed Aug. 28, 2001, entitled IMPROVEDVEHICULAR LIGHTING SYSTEM, the disclosures of which are herebyincorporated by reference herein in their entireties) is mounted withinthe center area of a recess 966 in the upper end of housing 962.Transparent polymeric material such as epoxy material or acrylicmaterial is placed over LED 964 in recess 966 to form a solid windowhaving a surface generally flush with the upper end of housing 962. Anappropriate icon or other indicia may be formed in or on epoxy 968.Suitable electrical leads 970 a, 970 b extend outwardly and downwardlyalong the sides of housing portion 962 for engagement with leads 960 inthe housing 956 when the plunger is depressed and operated.

When switch 950 is operated by depressing or moving plunger 952, leads970 slidably engage electrical contacts 960 to energize LED 964 andbacklight any icon or other indicia which is formed or provided in theepoxy backfill 968 within recess 966. Switch 950, therefore, eliminatesthe need for separate mounting of icon or indicia bearing elements, LEDsand switch members and provides an integral backlit informationilluminating electrical switch having long life due to the use of asolid-state LED in a compact switch unit which may be easily mounted ina single operation for use in an electrical assembly such as a rearviewmirror.

Accordingly, the present invention provides improved rearview mirrorsupports, vehicle accessory mounting members integrated with suchsupports and attachment members/windshield mounting buttons havingincreased size for adherence to the inside surface of a windshield tosupport the rearview mirror support and vehicle accessory mountingmember as well as the rearview mirror assemblies cantilevered therefromin proper fashion for increased stability, increased vibrationperformance and reduced tensile peeling stress.

1-128. (canceled)
 129. An interior rearview mirror assembly suitable foruse in a vehicle comprising: a rearview mirror mount formed frompolymeric material having a first color, said rearview mirror mountadapted for attachment to one of a windshield portion of the vehicle anda header portion of the vehicle; a rearview mirror housing assembly,said housing assembly including a rearview mirror housing formed frompolymeric material having a second color and a reflective rearviewmirror element; a rearview mirror support formed from polymeric materialhaving a third color; a first ball pivot member formed from polymericmaterial having a fourth color; a second ball pivot member formed frompolymeric material having a fifth color; said support being pivotalabout said mirror mount by said first ball pivot member, said rearviewmirror housing assembly being pivotal about said support by said secondball pivot member; at least one of said mirror mount and said supportincluding said first ball pivot member, the other of said mirror mountand said support including a first socket that receives and frictionallyengages said first ball pivot member; at least one of said rearviewmirror housing assembly and said support including said second ballpivot member, the other of said mirror housing assembly and said supportincluding a second socket that receives and frictionally engages saidsecond ball pivot member; wherein each of said mirror mount, said mirrorsupport, said rearview mirror housing, said first ball pivot member, andsaid second ball pivot member is formed in its respective color bymolding from polymeric material of that color; at least one electricalaccessory included in said rearview mirror housing assembly, saidinterior rearview mirror assembly including at least one electricalconductor for electrically connecting said electrical accessory to thevehicle electrical system; said rearview mirror support including acable-way through which said electrical conductor passes, saidelectrical conductor passing through said first ball pivot member, saidcable-way and said second ball pivot member for connection to thevehicle electrical system whereby the presence of said electricalconductor passing through said rearview mirror support and said firstand second ball pivot members is concealed from view while beingprotected therein even while said ball pivot members are pivoted foradjustment of the position of said rearview mirror housing assembly.130. The rearview mirror assembly of claim 129 wherein said electricalconductor extends from said rearview mirror housing assembly and passesthrough said second ball pivot member, said cable-way, and said firstball pivot member.
 131. The rearview mirror assembly of claim 130wherein said electrical conductor also extends through said mirrormount.
 132. The rearview mirror assembly of claim 129 wherein saidelectrical conductor comprises a wire.
 133. The rearview mirror assemblyof claim 129 wherein said rearview mirror element comprises a prismaticrearview mirror element and wherein said rearview mirror housingassembly comprises a toggle actuator, said toggle actuator including atleast one of said second ball pivot member and said second socket. 134.The rearview mirror assembly of claim 129 wherein said first, second,third, fourth, and fifth colors are substantially the same color. 135.The rearview mirror assembly of claim 134 wherein said substantially thesame color comprises black.
 136. The rearview mirror assembly of claim129 wherein at least two of said mirror mount, said mirror support, saidrearview mirror housing, said first ball pivot member and said secondball pivot member are molded from polymeric materials of differentcolors.
 137. The rearview mirror assembly of claim 129 wherein saidsupport comprises a vibration dampening member.
 138. The rearview mirrorassembly of claim 129 wherein said support comprises a stiffeninginsert.
 139. The rearview mirror assembly of claim 138 wherein saidstiffening insert is molded in said support.
 140. The rearview mirrorassembly of claim 129 wherein said support includes another electricalaccessory.
 141. The rearview mirror assembly of claim 129 wherein saidcable-way is disposed on the exterior of said support.
 142. The rearviewmirror assembly of claim 129 wherein said cable-way is disposedgenerally centrally in said support.
 143. The rearview mirror assemblyof claim 129 wherein said cable-way is formed by molding said cable-wayin said support.
 144. The rearview mirror assembly of claim 129 whereinsaid cable-way comprises a trough.
 145. The rearview mirror assembly ofclaim 129 including a stiffening insert molded in said mirror mount.146. The rearview mirror assembly of claim 129 wherein said reflectiverearview mirror element comprises an electro-optic mirror element. 147.The mirror assembly of claim 129 wherein the torque required to movesaid first ball pivot member in said first socket is greater than thetorque required to move said second ball pivot member in said secondsocket.
 148. The mirror assembly of claim 147 wherein the ratio of thetorque required for pivotal movement at said first ball pivot member tothe torque required for pivotal movement at said second ball pivotmember is at least about 2 to
 1. 149. The rearview mirror assembly ofclaim 129 wherein the torque required to move said first ball pivotmember in its socket is from about 0.8 to about 3.6 Newton-meters. 150.The rearview mirror assembly of claim 149 wherein the torque required tomove said second ball member in its socket is from about 0.6 to about3.2 Newton-meters.
 151. The rearview mirror assembly of claim 129wherein at least two of said first ball pivot member, said first socket,said support, said rearview mirror mount, said second ball pivot memberand said second socket are formed from the same polymeric material. 152.The rearview mirror assembly of claim 129 wherein at least one of saidfirst ball pivot member, said first socket, said support, said rearviewmirror mount, said second ball pivot member and said second socket isformed from a filled polymeric material.
 153. The rearview mirrorassembly of claim 129 wherein at least one of said first ball pivotmember, said first socket, said support, said rearview mirror mount,said second ball pivot member and said second socket is formed from afirst polymeric material and at least a second of said first ball pivotmember, said first socket, said support, said rearview mirror mount,said second ball pivot member and said second socket is formed from asecond polymeric material.
 154. The rearview mirror assembly of claim153 wherein first polymeric material comprises a filled polymericmaterial.
 155. The rearview mirror assembly of claim 154 wherein saidfilled polymeric material comprises a glass-filled polymeric material.156. The rearview mirror assembly of claim 155 wherein said glass-filledpolymeric material comprises a nylon material.
 157. The rearview mirrorassembly of claim 153 wherein said support is formed from said firstpolymeric material.
 158. An interior rearview mirror assembly suitablefor use in a vehicle comprising: a rearview mirror mount formed frompolymeric material having a first color, said rearview mirror mountadapted for attachment to an interior portion of the vehicle; a rearviewmirror housing assembly, said housing assembly including a rearviewmirror housing formed from polymeric material having a second color anda reflective rearview mirror element; a rearview mirror support formedfrom polymeric material having a third color; a first ball pivot memberformed from polymeric material having a fourth color; a second ballpivot member formed from polymeric material having a fifth color; saidsupport being pivotal about said mirror mount by said first ball pivotmember, said rearview mirror housing assembly being pivotal about saidsupport by said second ball pivot member; at least one of said mirrormount and said support including said first ball pivot member, the otherof said mirror mount and said support including a first socket thatreceives and frictionally engages said first ball pivot member; at leastone of said rearview mirror housing assembly and said support includingsaid second ball pivot member, the other of said mirror housing assemblyand said support including a second socket that receives andfrictionally engages said second ball pivot member; wherein each of saidmirror mount, said mirror support, said rearview mirror housing, saidfirst ball pivot member, and said second ball pivot member is formed inits respective color by molding from polymeric material of that color;the torque required to move said first ball pivot member in said firstsocket being greater than the torque required to move said second ballpivot member in said second socket; at least one electrical accessoryincluded in said rearview mirror housing assembly, said interiorrearview mirror assembly including at least one electrical conductor forelectrically connecting said electrical accessory to the vehicleelectrical system; said rearview mirror support including a cable-waythrough which said electrical conductor passes, said electricalconductor passing through said first ball pivot member, said cable-wayand said second ball pivot member for connection to the vehicleelectrical system whereby the presence of said electrical conductorpassing through said rearview mirror support and said first and secondball pivot members is concealed from view while being protected thereineven while said ball pivot members are pivoted for adjustment of theposition of said rearview mirror housing assembly.
 159. The rearviewmirror assembly of claim 158 wherein said electrical conductor extendsfrom said rearview mirror housing assembly and passes through saidsecond ball pivot member, said cable-way, and said first ball pivotmember.
 160. The rearview mirror assembly of claim 159 wherein saidelectrical conductor also extends through said mirror mount.
 161. Therearview mirror assembly of claim 158 wherein said electrical conductorcomprises a wire.
 162. The mirror assembly of claim 158 wherein theratio of the torque required for pivotal movement at said first ballpivot member to the torque required for pivotal movement at said secondball pivot member is at least about 2 to
 1. 163. The rearview mirrorassembly of claim 158 wherein at least two of said first ball pivotmember, said first socket, said support, said rearview mirror mount,said second ball pivot member and said second socket are formed from thesame polymeric material.
 164. The rearview mirror assembly of claim 158wherein at least one of said first ball pivot member, said first socket,said support, said rearview mirror mount, said second ball pivot memberand said second socket is formed from a filled polymeric material. 165.The rearview mirror assembly of claim 158 wherein at least one of saidfirst ball pivot member, said first socket, said support, said rearviewmirror mount, said second ball pivot member and said second socket isformed from a first polymeric material and at least a second of saidfirst ball pivot member, said first socket, said support, said rearviewmirror mount, said second ball pivot member and said second socket isformed from a second polymeric material.
 166. The rearview mirrorassembly of claim 165 wherein first polymeric material comprises afilled polymeric material.
 167. The rearview mirror assembly of claim166 wherein said filled polymeric material comprises a glass-filledpolymeric material.
 168. The rearview mirror assembly of claim 167wherein said glass-filled polymeric material comprises a nylon material.169. The rearview mirror assembly of claim 165 wherein said support isformed from said first polymeric material.
 170. An interior rearviewmirror assembly suitable for use in a vehicle comprising: a rearviewmirror mount formed from polymeric material having a first color, saidrearview mirror mount adapted for attachment to an interior portion ofthe vehicle; a rearview mirror housing assembly, said housing assemblyincluding a rearview mirror housing formed from polymeric materialhaving a second color and a reflective rearview mirror element; arearview mirror support formed from polymeric material having a thirdcolor; a first ball pivot member formed from polymeric material having afourth color; a second ball pivot member formed from polymeric materialhaving a fifth color; said support being pivotal about said mirror mountby said first ball pivot member, said rearview mirror housing assemblybeing pivotal about said support by said second ball pivot member; atleast one of said mirror mount and said support including said firstball pivot member, the other of said mirror mount and said supportincluding a first socket that receives and frictionally engages saidfirst ball pivot member; at least one of said rearview mirror housingassembly and said support including said second ball pivot member, theother of said mirror housing assembly and said support including asecond socket that receives and frictionally engages said second ballpivot member; wherein each of said mirror mount, said mirror support,said rearview mirror housing, said first ball pivot member, and saidsecond ball pivot member is formed in its respective color by moldingfrom polymeric material of that color; at least one of said first ballpivot member, said first socket, said mirror support, said rearviewmirror mount, said second ball pivot member and said second socket isformed from a first polymeric material and at least a second of saidfirst ball pivot member, said first socket, said mirror support, saidrearview mirror mount, said second ball pivot member and said secondsocket is formed from a second polymeric material; the torque requiredto move said first ball pivot member in said first socket being greaterthan the torque required to move said second ball pivot member in saidsecond socket; at least one electrical accessory included in saidrearview mirror housing assembly, said interior rearview mirror assemblyincluding at least one electrical conductor for electrically connectingsaid electrical accessory to the vehicle electrical system; saidrearview mirror support including a cable-way through which saidelectrical conductor passes, said electrical conductor passing throughsaid first ball pivot member, said cable-way and said second ball pivotmember for connection to the vehicle electrical system whereby thepresence of said electrical conductor passing through said rearviewmirror support and said first and second ball pivot members is concealedfrom view while being protected therein even while said ball pivotmembers are pivoted for adjustment of the position of said rearviewmirror housing assembly.
 171. The rearview mirror assembly of claim 170wherein said electrical conductor extends from said rearview mirrorhousing assembly and passes through said second ball pivot member, saidcable-way, and said first ball pivot member.
 172. The rearview mirrorassembly of claim 171 wherein said electrical conductor also extendsthrough said mirror mount.
 173. The rearview mirror assembly of claim172 wherein said electrical conductor comprises a wire.
 174. The mirrorassembly of claim 170 wherein the ratio of the torque required forpivotal movement at said first ball pivot member to the torque requiredfor pivotal movement at said second ball pivot member is at least about2 to
 1. 175. The rearview mirror assembly of claim 170 wherein at leasttwo of said first ball pivot member, said first socket, said support,said rearview mirror mount, said second ball pivot member and saidsecond socket are formed from the same polymeric material.
 176. Therearview mirror assembly of claim 170 wherein first polymeric materialcomprises a filled polymeric material.
 177. The rearview mirror assemblyof claim 176 wherein said filled polymeric material comprises aglass-filled polymeric material.
 178. The rearview mirror assembly ofclaim 177 wherein said glass-filled polymeric material comprises a nylonmaterial.
 179. The rearview mirror assembly of claim 170 wherein saidsupport is formed from said first polymeric material.
 180. An interiorrearview mirror assembly suitable for use in a vehicle comprising: arearview mirror mount formed from polymeric material having a firstcolor, said rearview mirror mount adapted for attachment to an interiorportion of the vehicle; a rearview mirror housing assembly, said housingassembly including a rearview mirror housing formed from polymericmaterial having a second color and a reflective rearview mirror element;a rearview mirror support formed from polymeric material having a thirdcolor; a first ball pivot member formed from polymeric material having afourth color; a second ball pivot member formed from polymeric materialhaving a fifth color; said support being pivotal about said mirror mountby said first ball pivot member, said rearview mirror housing assemblybeing pivotal about said support by said second ball pivot member; atleast one of said mirror mount and said support including said firstball pivot member, the other of said mirror mount and said supportincluding a first socket that receives and frictionally engages saidfirst ball pivot member; at least one of said rearview mirror housingassembly and said support including said second ball pivot member, theother of said mirror housing assembly and said support including asecond socket that receives and frictionally engages said second ballpivot member; wherein each of said mirror mount, said mirror support,said rearview mirror housing, said first ball pivot member, and saidsecond ball pivot member is formed in its respective color by moldingfrom polymeric material of that color; at least one of said first ballpivot member, said first socket, said mirror support, said rearviewmirror mount, said second ball pivot member and said second socket isformed from a first polymeric material and at least a second of saidfirst ball pivot member, said first socket, said mirror support, saidrearview mirror mount, said second ball pivot member and said secondsocket is formed from a second polymeric material; the torque requiredto move said first ball pivot member in said first socket being greaterthan the torque required to move said second ball pivot member in saidsecond socket; at least one electrical accessory included in saidrearview mirror housing assembly, said interior rearview mirror assemblyincluding at least one electrical conductor for electrically connectingsaid electrical accessory to the vehicle electrical system; saidrearview mirror support including a cable-way through which saidelectrical conductor passes, said electrical conductor passing throughsaid first ball pivot member, said cable-way and said second ball pivotmember for connection to the vehicle electrical system whereby thepresence of said electrical conductor passing through said rearviewmirror support and said first and second ball pivot members is concealedfrom view while being protected therein even while said ball pivotmembers are pivoted for adjustment of the position of said rearviewmirror housing assembly; wherein said electrical conductor extends fromsaid rearview mirror housing assembly and passes through said secondball pivot member, said cable-way, and said first ball pivot member andwherein said electrical conductor also extends through said mirrormount; wherein at least one of said first ball pivot member, said firstsocket, said support, said rearview mirror mount, said second ball pivotmember and said second socket is formed from a first polymeric materialand at least a second of said first ball pivot member, said firstsocket, said support, said rearview mirror mount, said second ball pivotmember and said second socket is formed from a second polymericmaterial; and wherein first polymeric material comprises a filledpolymeric material.
 181. The rearview mirror assembly of claim 180wherein said filled polymeric material comprises a glass-filledpolymeric material.
 182. The rearview mirror assembly of claim 181wherein said glass-filled polymeric material comprises a nylon material.183. The rearview mirror assembly of claim 180 wherein said support isformed from said first polymeric material.